TECHNICAL SPECIFICATIONS FOR CITY OF CONROE 2014 …

TECHNICAL SPECIFICATIONS FOR

CITY OF CONROE 2014 SURFACE WATER SYSTEM IMPROVEMENTS: WATER PLANTS

Issued for Competitive Sealed Proposals August 11, 2014

Divisions: 1 – 11, 15

Divisions: 13, 16 (except 13122) Division: 13122

2925 Briarpark Drive, Suite 300 Houston, TX 77042

Tel 713.266.6900 Fax 713.266.2089 Firm ID F-2614

8/11/14

Lockwood, Andrews & Newnam, Inc. ID # F-2614

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TABLE OF CONTENTS TOC-1

TECHNICAL SPECIFICATIONS

FOR

CITY OF CONROE

2014 SURFACE WATER SYSTEM IMPROVEMENTS: WATER PLANTS

TABLE OF CONTENTS

TECHNICAL SPECIFICATIONS

DIVISION 01 GENERAL REQUIREMENTS

SECTION 01010 SUMMARY OF WORK

SECTION 01051 CONSTRUCTION STAKING BY CONTRACTOR

SECTION 01091 ABBREVIATIONS AND SYMBOLS

SECTION 01295 SCHEDULE OF VALUES

SECTION 01325 CONSTRUCTION SCHEDULES

SECTION 01330 SUBMITTAL PROCEDURES

SECTION 01340 SHOP DRAWINGS, PRODUCT DATA AND SAMPLES

SECTION 01380 QUALITY CONTROL

SECTION 01400 REFERENCE STANDARDS

SECTION 01500 CONSTRUCTION FACILITIES AND TEMPORARY CONTROLS

SECTION 01600 MATERIALS AND EQUIPMENT

SECTION 01655 STARTING OF SYSTEMS

SECTION 01661 INSTRUCTION OF OPERATION AND MAINTENANCE PERSONNEL

SECTION 01730 CUTTING AND PATCHING

SECTION 01740 CLEANING AND ADJUSTING

SECTION 01750 WASTE MATERIAL DISPOSAL

SECTION 01770 CLOSEOUT PROCEDURES

SECTION 01781 PROJECT RECORD DOCUMENTS

SECTION 01785 WARRANTIES AND BONDS

SECTION 01790 SPARE PARTS AND MAINTENANCE MATERIALS


SECTION 01795 POST FINAL INSPECTION

SECTION 01800 OPERATIONS AND MAINTENANCE DATA

DIVISION 02 SITE WORK

SECTION 02060 DEMOLITION

SECTION 02085 VALVE BOXES, METER BOXES, AND METER VAULTS

SECTION 02086 ADJUSTING MANHOLES, INLETS, AND VALVE BOXES TO GRADE

SECTION 02110 SITE CLEARING

SECTION 02112 EROSION CONTROL AND RIPRAP

SECTION 02211 ROUGH GRADING

SECTION 02221 REMOVING EXISTING PAVEMENTS AND STRUCTURES

SECTION 02223 EARTHWORK

SECTION 02240 DEWATERING AND DRAINAGE OF EXCAVATION

SECTION 02315 EXCAVATION, TRENCHING, AND BACKFILL FOR UTILITIES

SECTION 02317 STRUCTURAL EXCAVATION, FILL, AND BACKFILL

SECTION 02320 TRENCH SAFETY SYSTEMS

SECTION 02321 CEMENT STABILIZED SAND

SECTION 02322 FLOWABLE FILL

SECTION 02336 LIME STABILIZED SUBGRADE

SECTION 02337 LIME / FLY-ASH STABILIZED SUBGRADE

SECTION 02370 GEOTEXTILE

SECTION 02516 CUT, PLUG, AND ABANDONMENT OF WATER LINES

SECTION 02528 POLYETHYLENE ENCASEMENT / WRAP

SECTION 02607 PRECAST MANHOLES AND COVERS

SECTION 02675 CLEANING AND DISINFECTION OF WATER PIPING, EQUIPMENT AND FACILITIES

SECTION 02714 FLEXIBLE BASE COURSE FOR DRIVEWAYS

SECTION 02751 CONCRETE PAVING


SECTION 02752 CONCRETE PAVEMENT JOINTS

SECTION 02753 CONCRETE PAVEMENT CURING

SECTION 02775 CONCRETE SIDEWALKS

SECTION 02912 TREE, PLANT, AND HARDSCAPE PROTECTION

SECTION 02923 LANDSCAPE GRADING

SECTION 02936 TOPSOILING AND SEEDING

SECTION 02937 SODDING

DIVISION 03 CONCRETE

SECTION 03110 CONCRETE FORMWORK

SECTION 03150 CONCRETE JOINTS AND EMBEDDED ITEMS

SECTION 03210 CONCRETE REINFORCEMENT

SECTION 03305 INCIDENTAL CONCRETE

SECTION 03310 CAST-IN-PLACE CONCRETE

SECTION 03360 CONCRETE FINISHING

SECTION 03605 NONSHRINK GROUT

DIVISION 05 METALS

SECTION 05120 STRUCTURAL STEEL

SECTION 05450 SUPPORT FRAMING

SECTION 05500 METAL FABRICATIONS

SECTION 05510 MISCELLANEOUS METALS

SECTION 05550 BOLTS, ANCHOR BOLTS, EXPANSION ANCHORS AND CONCRETE INSERTS

DIVISION 06 WOOD AND PLASTICS

SECTION 06601 GLASS FIBER AND RESIN FABRICATIONS


DIVISION 07 THERMAL AND MOISTURE PROTECTION

SECTION 07115 DAMPPROOFING AND WATERPROOFING

DIVISION 09 FINISHES

SECTION 09928 PROTECTIVE COATING SYSTEMS

DIVISION 11 EQUIPMENT

SECTION 11100 CLOSE COUPLED HORIZONTAL END SUCTION PUMP

SECTION 11300 VERTICALLY MOUNTED, HORIZONTAL SPLIT CASE PUMP

SECTION 11400 PUMP REFURBISHMENT

SECTION 11500 VACUUM GAS CHLORINATION EQUIPMENT

DIVISION 13 SPECIAL CONSTRUCTION

SECTION 13122 PRE-CAST CONCRETE BUILDING

SECTION 13400 INSTRUMENTATION AND CONTROL GENERAL PROVISIONS

SECTION 13410 PROGRAMMABLE LOGIC CONTROLLERS (PLC)

SECTION 13412 UNINTERRUPTIBLE POWER SUPPLY

SECTION 13413 CONTROL PANELS

SECTION 13417 DATA NETWORKING EQUIPMENT

SECTION 13420 INSTRUMENT COMMISIONING

SECTION 13421 INSTRUMENTS

SECTION 13422 INSTRUMENTATION ACCESSORIES

SECTION 13430 SYSTEM CONFIGURATION

SECTION 13440 INPUT OUTPUT LIST

SECTION 13815 LIGHTING CONTROLS

DIVISION 15 MECHANICAL

SECTION 15010 BASIC MECHANICAL REQUIREMENTS


SECTION 15011 BASIC MECHANICAL PROCEDURES AND METHODS

SECTION 15030 ERECTING AND JOINTING INTERIOR PLANT PROCESS PIPING

SECTION 15032 TESTING PIPING SYSTEMS

SECTION 15040 BUTTERFLY VALVES 3-INCH THROUGH 72-INCH

SECTION 15043 GATE VALVES

SECTION 15045 FIRE HYDRANTS

SECTION 15050 MECHANICAL GENERAL PROVISIONS

SECTION 15060 EQUIPMENT BASES AND SUPPORTS

SECTION 15105 PIPE AND PIPE FITTINGS

SECTION 15106 DUCTILE IRON PIPE AND FITTINGS

SECTION 15140 SUPPORTS AND ANCHORS

SECTION 15190 MECHANICAL IDENTIFICATION

SECTION 15192 NATURAL GAS PIPING AND APPURTENANCES

SECTION 15410 PLUMBING

SECTION 15830 FANS

DIVISION 16 ELECTRICAL

SECTION 16050 ELECTRICAL GENERAL PROVISIONS

SECTION 16051 ACCEPTANCE TESTING AND CALIBRATION

SECTION 16052 IDENTIFICATIONS

SECTION 16060 GROUNDING

SECTION 16120 INSULATED CONDUCTORS

SECTION 16130 RACEWAYS

SECTION 16135 BOXES

SECTION 16140 WIRING DEVICES

SECTION 16145 TIME SWITCHES

SECTION 16170 METAL FRAMING

SECTION 16191 MISCELLANEOUS EQUIPMENT

SECTION 16222 AC ELECTRIC MOTORS - 100 HP AND BELOW


SECTION 16230 PACKAGED ENGINE GENERATOR SYSTEMS

SECTION 16276 DRY TYPE TRANSFORMERS - 600V PRIMARY AND BELOW

SECTION 16285 SURGE PROTECTIVE DEVICES (SPD) - 600V AND BELOW

SECTION 16410 ENCLOSED SAFETY SWITCHES

SECTION 16415 AUTOMATIC TRANSFER SWITCHES

SECTION 16425 MOTOR STARTERS - 600 V AND BELOW

SECTION 16445 MOTOR CONTROL CENTERS

SECTION 16490 FUSES - 600V AND BELOW

SECTION 16510 LIGHTING FIXTURES AND LAMPS

CITY OF CONROE 2014 SURFACE WATER SYSTEM IMPROVEMENTS

WATER PLANTS

SUMMARY OF WORK

01010-1

SECTION 01010

SUMMARY OF WORK

PART 1 - GENERAL

1.1 SITE LOCATIONS

A. Water Plant 6 (Northwest): 2021 Westview Drive, Conroe, TX 77304

B. Water Plant 14 (Wedgewood): 2631 Longmire Road, Conroe, TX 77304

C. Water Plant 15 (Silver Springs): 829 Silver Springs Road, Conroe, TX 77309

D. Water Plant 20 (Pollok): 3250 Pollok Drive 3300 Pollok Drive, Conroe, TX 77303

E. Water Plant 21 (Little Egypt): 10585 Little Egypt Road, Conroe, TX 77304

F. Water Plant 22 (FM 3083): 375 N. FM 3083 E., Conroe, TX 77303

1.2 GENERAL DESCRIPTION OF THE WORK

A. The Work to be performed for the City of Conroe, TX shall include, but is not limited to

the following:

1. Water Plant 6

a. Construction of new precast concrete water plant building, 50’x30’ with 2-

ton bridge crane.

b. Installation of three (3) 1,000 gpm (nominal) vertically mounted, split

case centrifugal pumps, including motors, suction and discharge header

piping, and pump suction and discharge valves and piping.

c. New flow meter vault and bypass piping with City-furnished 12” magnetic

flow meter.

d. Relocation of existing vacuum gas chlorinator equipment from existing

Water Plant 6 building to new Chlorine Room. Installation of new post-

chlorination feed equipment in new Chlorine Room and chlorine residual

analyzer in new Pump Room.

e. Relocation of existing phosphate storage tank and ultrasonic level

transducer to new Phosphate Room. Installation of new two (2) new

phosphate feed pumps.

f. Yard piping to connect to existing 18” ground storage tank outlet piping

and 12” distribution piping; new chlorine solution piping.

g. Aggregate access driveway, concrete sidewalk, and site grading around

new building.

h. New natural gas powered generator.

i. Instrumentation and SCADA control improvements.

j. New MCC in new water plant building


WATER PLANTS

SUMMARY OF WORK

01010-2

2. Water Plant 14

a. Removal and salvage of one (1) existing pump and motor.

b. Installation of one (1) new 750 gpm (nominal) horizontally mounted, end

suction centrifugal pump, including motor and discharge piping.

c. Replacement of two (2) 40 hp pump motors and bases with new 50 hp

motors on existing horizontally mounted, end suction centrifugal pumps.

d. Installation of new post-chlorination feed equipment and chlorine residual

analyzer.

e. New natural gas powered generator.

f. Instrumentation and SCADA control improvements.

g. New MCC in existing water plant building

3. Water Plant 15

a. Removal and salvage of all existing pumps and motors, three (3) total.

b. Installation of three (3) new 1,000 gpm (nominal) horizontally mounted,

end suction centrifugal pumps, including motors, modifications to existing

suction and discharge header piping, and new pump suction and

discharge valves and piping.

c. Installation of new post-chlorination feed equipment and chlorine residual

analyzer.

d. New natural gas powered generator.

e. Instrumentation and SCADA control improvements.

f. New MCC in existing water plant building.

4. Water Plant 20

a. Removal of two (2) existing pumps and motors for relocation to Water

Plants 21 and 22.

b. Installation of three (3) new 1,000 gpm (nominal) vertically mounted, split

case centrifugal pumps, including motors, modifications to existing

suction and discharge header piping, and new pump suction and

discharge valves and piping.


analyzer.

d. Instrumentation and SCADA control improvements.

5. Water Plant 21

a. Installation of one (1) relocated 1,000 gpm (nominal) horizontally

mounted, split case centrifugal pump from Water Plant 20, including

motor, modifications to existing suction and discharge header piping, and

new pump suction and discharge valves and piping. Relocated pump

shall be shop flow tested to determine impeller trim required to meet


WATER PLANTS

SUMMARY OF WORK

01010-3

specified duty point. Relocated pump shall be refurbished as required

based on inspection.

b. Existing two pumps shall have impellers replaced with one impeller from

second Water Plant 20 pump and one new impeller, trimmed to meet

specified duty point. Both existing pumps shall be refurbished as

required based on inspection.


analyzer.


6. Water Plant 22

a. Installation of one (1) relocated 1,000 gpm (nominal) horizontally

mounted, split case centrifugal pump from Water Plant 20, including

motor, modifications to existing suction and discharge header piping, and

new pump suction and discharge valves and piping. Relocated pump

shall be shop flow tested to determine impeller trim required to meet

specified duty point. Provide new impeller and refurbish relocated pump

as required based on inspection.

b. For existing pumps, provide new impellers and refurbish pumps as

required if shop flow test noted in 6.a. above indicates that existing

impellers are too small to meet specified duty point.


analyzer.


7. Other items as specified, shown and as required.

B. Contractor shall have experience with construction of booster pump stations of similar

size or larger. If requested by City, Contractor shall provide a minimum of 5 references

of similar projects.

1.3 SEQUENCE OF WORK

A. Contractor shall plan and determine the sequence of construction operations.

B. Shutdowns of existing pumping facilities, for purposes of Construction Work, will be

permitted. Contractor shall notify Owner a minimum of 7 days prior to any shutdown. All

valves requiring operation for shutdown shall be performed by City personnel. Contractor

must submit a plan for the shutdown, including planned duration, for approval by Owner

and Engineer.

C. Contractor's sequence of work shall take into account the following project requirements:

1. All piping will be installed, tested, disinfected, and ready to be placed in service

prior to placing new pumping equipment in service.

2. Owner requires a minimum 48-hour notice for any non-shutdown support needed

from City personnel.


WATER PLANTS

SUMMARY OF WORK

01010-4

1.4 CONTRACTOR'S USE OF PREMISES

A. Contractor will receive a limited number of contractor cards providing access to

necessary areas of water plants.

B. Contractor vehicles and uniforms must be marked with company name.

C. Contractor work hours limited to 7:00 a.m. to 7:00 p.m. Monday through Friday. Weekend

and Holiday work will require approval by the City’s Executive Director of Infrastructure.

D. Contractor will be allocated space for storage and the operations of its workmen, unless

otherwise provided under Supplementary Conditions.

E. Contractor shall submit requirements for storage to the Owner and cooperate with the

Owner to utilize locations approved by the Owner for Contractor use.

F. Contractor shall:

1. Assume full responsibility for protection and safekeeping of products stored on or

off premises.

2. Move stored products that interfere with the operations of Owner.

3. Obtain and pay for all additional storage or Work areas required for its

operations.

4. Install and maintain temporary access and haul roads.

5. Repair existing access roads and parking areas damaged during construction at

the request of the Owner within 72 hours to maintain operations at existing pump

stations.

6. Backfill or cover open excavations with steel plates during non-working hours, as

approved by Owner.

7. Clean-up water plant site to avoid obstacles, scattered materials, or limited site

access to Owner, especially if work at a water plant site is halted waiting for

materials, shutdown or other reason.

1.5 SHUTDOWNS

A. Only one (1) water plant may be taken out of service at any time to perform the work.

B. Contractor shall notify Owner and Engineer seven (7) days minimum prior to any

scheduled shutdown. Contractor shall provide weekly schedules for upcoming work.

C. Owner shall operate all valves and pumping equipment to facilitate plant shutdowns and

startups.

D. In case of an emergency and a plant must be placed back in service prior to completing

scheduled work, Contractor shall assist Owner and perform all work necessary, working

continuously, to place the plant back in service. Contractor shall be allowed additional

compensation for this work.


WATER PLANTS

SUMMARY OF WORK

01010-5

E. Schedule: Plant shutdowns and work shall generally be in the following order:

1. Plant 21

a. Plant shutdown shall only be allowed in January and February during low

demand months.

b. Contractor may perform short duration shutdown to install new pump

suction and discharge isolation valves and then place plant back in

service. The interior of all new pipe, valves, and fittings shall be

swabbed or sprayed with a 1% hypochlorite solution before they are

installed in accordance with AWWA C651. This will allow Contractor to

install new pump during high demand months without taking the plant out

of service.

2. Plant 15

a. Requires plant shutdown to make modifications to existing pump suction

and discharge header piping and pump replacement.

b. Requires plant shutdown to replace existing MCC with new MCC.

3. Plant 20



4. Plant 22



5. Plant 14

a. Requires plant shutdown to replace existing MCC with new MCC.

6. Plant 6

a. Requires temporary shutdown of existing pump station for new yard

piping connections. The interior of all new pipe, valves, and fittings used

in the connection shall be swabbed or sprayed with a 1% hypochlorite

solution before they are installed in accordance with AWWA C651.

b. Once yard piping connections have been completed, existing pump

station can be placed back in service while new pump station is being

constructed.

END OF SECTION


WATER PLANTS

SUMMARY OF WORK

01010-6

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WATER PLANTS

CONSTRUCTION STAKING BY CONTRACTOR

01051-1

SECTION 01051


PART 1 - GENERAL

1.1 SECTION INCLUDES A. The Contractor is responsible for all detailed staking and layout necessary for construction of the Project.

1.2 NOTIFICATIONS A. In the event that it appears there is an error or contradiction between plan grades, construction stakes, and/or actual conditions, the Contractor shall notify the Owner’s Designation Representative immediately.

PART 2 - PRODUCTS

Not Applicable

PART 3 - EXECUTION

3.1 REQUIREMENTS A. The Contractor is responsible to provide such layout and control work as may be required for construction of the proposed improvements. Layout and staking shall be provided as many times as necessary to accommodate the Contractor’s work plan and schedule. Restaking because of damage by construction activities, vandalism, or other losses shall be provided at the Contractor’s expense. B. The Contractor shall provide workers competent in the layout and control work necessary. The Contractor shall provide the equipment and materials necessary for establishing the necessary control and layout.

C. The Contractor shall be responsible for protecting and preserving all property corners and survey control points (i.e. benchmarks and horizontal control points). If existing property corners or survey control points are disturbed, the Contractor shall be responsible for the costs of re-establishing the information. All survey work will be performed by a professional land surveyor.

3.2 PLAN GRADES AND ALIGNMENT

A. The horizontal alignment of pipelines, manholes, and structures will be from pipe centerlines, center of castings, or corners of structures, respectively, unless otherwise noted. B. Final casting elevation for drainage structures and manholes shall be determined by the Engineer, after grading is completed.

END OF SECTION


WATER PLANTS


01051-2

BLANK PAGE


WATER PLANTS

ABBREVIATIONS AND SYMBOLS

01091-1

SECTION 01091 ABBREVIATIONS AND SYMBOLS

PART 1 - GENERAL

1.1 ABBREVIATIONS

Common abbreviations which may be found in the Specifications are:

Alternating current AC

Adjustable Frequency Drive AFD

ante meridian a.m.

ampere A

average avg

boiler horsepower BHP

brake horsepower bhp

British thermal unit Btu & BHR

company co

cubic inch cu in

cubic foot cu ft

cubic yard cu yd

cubic feet per minute cfm

cubic feet per second cfs

decibel db

degree Centigrade oC

degree Fahrenheit oF

diameter dia

direct current DC

dollars $

each ea

efficiency eff

feet ft

feet per hour fph

feet per minute fpm

feet per second fps

flange flg., FL

foot-pound ft-lb

Velocity Gradient G

gallon gal

gallons per hour gph

gallons per minute gpm

gallons per second gps

gram g

Hertz Hz

hour hr

horsepower HP, Hp

inch in.

Inch-lb. in-lb.

inside diameter ID

kilovolt-ampere KVA

kilowatt KW

kilowatt-hour KWH

linear foot lin ft.


WATER PLANTS


01091-2

liter l

maximum max

million circular MCM mils

mercury Hg

milligram mg

milligrams per liter mg/l

milliliter ml

millimeter mm

million gallon MG

million gallons per day mgd

minimum min

suction head number No.

National Pipe Threads NPT

ounce oz.

outside diameter OD

open-drip proof ODP

parts per million ppm

post meridian p.m.

pound lb

pounds per square foot psf

pounds per square inch psi

pounds per square psia inch absolute pounds per square psig inch gage Revolutions per minute RPM

second sec

specific gravity sp. gr.

square sq

square foot sq ft

square inch sq in

square yard sq yd

standard std

standard cubic feet per minute scfm

side water depth swd

total dynamic head TDH

totally-enclosed fan-cooled TEFC

totally-enclosed air over TEAO

Volt V


WATER PLANTS


01091-3

1.2 ORGANIZATION ABBREVIATIONS

Abbreviations of organizations which may be used in these Specifications are:

ADC Air Diffusion Council - Test Code

ACS American Chemical Society

ACI American Concrete Institute

AFBMA Anti-Friction Bearing Manufacturer’s Association

AGA American Gas Association

AGMA American Gear Manufacturer’s Association

AIChE American Institute of Chemical Engineers

AISC American Institute of Steel Construction

AISI American Iron and Steel Institute

AMCA Air Moving and Conditioning Association

ANSI American National Standards Institute

APHA American Public Health Association

API American Petroleum Institute

ASTM American Society for Testing and Materials

ARI Air Conditioning and Refrigeration Institute

ASCE American Society of Civil Engineers

ASME American Society of Mechanical Engineers

ASHRAE American Society of Heating, Refrigerating and Air Conditioning Engineers

ASTM American Society for Testing and Materials

AWWA American Water Works Association

AWS American Welding Society

CFR Code of Federal Regulations

CGA Compressed Gas Association

CRSI Concrete Reinforcing Steel Institute

DILHR Department of Industry, Labor and Human Relations


WATER PLANTS


01091-4

DNR Department of Natural Resources

EIA Electronics Industries Association

EPA Environmental Protection Agency

FM Factory Mutual System

HI Hydraulic Institute

ICEA Insulated Cable Engineers Association

IEEE Institute of Electrical and Electronic Engineers

ISA Instrument Society of American

IES Illuminating Engineering Society

IRI Industrial Risk Insurance

ISO Insurance Services Office

JIC Joint Industry Council

MSS Manufacturers Standardization Society

NAAMM National Association of Architectural Metal Manufacturers

NEC National Electrical Code

NEMA National Electrical Manufacturers Association

NFC National Fire Code

NFPA National Fire Protection Association

NPC National Plumbing Code

NSF National Sanitation Foundation

OSHA Occupational Safety and Health Act

PCI Precast Concrete Institute

SMACNA Sheet Metal and Air Conditioning National Association

SSPC Society for Protective Coatings

UBC Uniform Building Code

UL Underwriters Laboratories, Inc.

USGS United States Geological Survey


WATER PLANTS


01091-5

USPHS United States Public Health Service

TxDOT State of Texas, Department of Transportation

WWEMA Water and Wastewater Equipment Manufacturers Association

WEF Water Environment Federation

WWEMA Water and Wastewater Equipment manufacturer’s Association

1.3 LEGEND

A. Legends of symbols used are shown on the Drawings, and in general, use of symbols is confined to the Drawings.

PART 2 - PRODUCTS

Not used.

PART 3 - EXECUTION

Not used.

END OF SECTION


WATER PLANTS


01091-6

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WATER PLANTS

SCHEDULE OF VALUES

01295-1

SECTION 01295

SCHEDULE OF VALUES

PART 1 - GENERAL

1.1 SUMMARY

A. Submit a Schedule of Values to Engineer for review and approval prior to the commencement of construction. Upon request, support values given with data that will substantiate the amounts. Use Schedule of Values only as basis for payment application.

B. Submit Schedule of Material Values specifying quantities of materials to be used during the course of the work. List quantities of materials specified under unit price allowances.

C. Payment for materials stored on-site or off-site in a bonded warehouse will be limited to those materials listed in a Schedule of Material Values.

1.2 FORM OF SUBMITTAL

A. Preparation and presentation of Schedule of Values: The Schedule of Values presented shall be in either a typewritten format or a “computer generated” format typically associated with office spreadsheets such as Excel®. Any software appropriate for the presentation of information and data in the desired format may be employed.

B. Format: The Schedule of Values will be presented on 8-1/2″ by 11″, plain bond, white paper, in “landscape mode”.

1. Major subdivisions in the Schedule of Values will conform to the Bid Items presented on the Bid Form. In the event only a single Bid Item is presented on the Bid Form the divisions of the Schedule of Values will conform to either the major components of the project, e.g. head works, aeration basin, final clarifiers, etc. or the major divisions listed in the Table of Contents of this project manual, e.g. Divisions 2 through 16.

2. As a minimum, the Schedule of Values shall include the following information presented column format, arranged left to right across the page.

a. Bid Item Number

b. Description of Work

c. Quantity

d. Unit Measure

e. Unit Price

f. Contract Cost

1.3 PREPARING SCHEDULE OF VALUES

A. Itemize separate line item cost for each of the following general cost items:

1. Performance and payment bonds.


WATER PLANTS

SCHEDULE OF VALUES

01295-2

2. Field supervision and layout.

3. Temporary facilities and controls.

4. Insurance.

5. Mobilization.

B. Subdivide costs of products to be installed during construction into separate line items. Suggested subdivisions for typical divisions, as applicable, are provided in the following subparagraphs.

1. Equipment

a. Equipment.

b. Installation.

c. Testing.

d. O&M Manuals.

e. Training.

2. Piping

3. Painting

4. Site Work

a. Clearing and grubbing.

b. Dewatering and drainage of excavation.

c. Earth work for site area.

d. Site grading.

e. Drainage swale excavation.

f. Manholes.

g. Fencing.

h. Erosion control.

i. Seeding.

5. Concrete Work

a. Excavation.

b. Seal slab.

c. Concrete piles.

d. Sheet piling.

e. Concrete, slab.

f. Concrete, walls.

g. Concrete, specials.


WATER PLANTS

SCHEDULE OF VALUES

01295-3

h. Slope paving.

i. Backfill.

j. Leak testing.

6. Roadways, Parking Areas, Sidewalks

a. Earthwork for paving.

b. Lime stabilization.

c. Concrete paving.

d. Concrete sidewalks.

e. Curbs.

f. Striping.

g. Signage.

h. Pavement repair and resurfacing.

7. Electrical Power Distribution

a. Electrical Panels and Transformers.

b. Conduit, Wire and Duct Banks.

c. Electrical Demolition.

d. Motor Control Centers and Service.

e. Wire Termination.

f. Instrumentation.

8. Continue the detailed presentation/division of work for the various buildings, pumping units, equipment systems, instrumentation, electrical and other work by the various sections, providing details as required by the Engineer.

C. Sum total costs for all items listed in the Schedule of Values equal to the total Contract sum.

1.4 REVIEW AND RESUBMITTAL

After review by the Engineer, revise and resubmit the Schedule of Values or Material Values, if required. Resubmit revised schedules in the same manner as the original schedules. Initial application for payment will not be processed until Schedule of Values is approved. Payment for stored materials will not be made until the Schedule of Unit Material Values has been approved.

PART 2 - PRODUCTS

Not used.


WATER PLANTS

SCHEDULE OF VALUES

01295-4

PART 3 - EXECUTION

Not used.

END OF SECTION


WATER PLANTS

CONSTRUCTION SCHEDULES

01325-1

SECTION 01325


PART 1 - GENERAL

1.1 SUMMARY

Prior to the commencement of construction activities, the Contractor shall prepare and submit to the Engineer a proposed construction schedule for the work, with sub-schedules of related activities which are essential to its progress.

1.2 RELATED REQUIREMENTS

A. Section 01010 – Summary of the Work.

B. Section 01330 – Submittal Procedures.

C. Section 01340 – Shop Drawings, Product Data and Samples.

D. Monthly Construction Progress Meetings. Meetings to be held at Owner’s Public Works building at 401 S. SGT Ed Holcomb, Conroe, TX 77305. Meetings should be scheduled at least one (1) month in advance with Ms. Kathy Walker at 936-522-3885.

1.3 FORM OF SCHEDULES

A. Prepare schedules in the form of a horizontal bar chart.

1. Provide separate horizontal bar for each trade or operation.

2. Horizontal Time Scale. Identify first work day of each week.

3. Scale and Spacing. To allow space for notations and future revisions.

B. Format of Listings. Chronological order of the start of each item of work.

C. Identification of Listings. By major specification section numbers.

1.4 CONTENT OF SCHEDULES

A. Construction Schedule.

1. Show complete sequence of construction by activity.

2. Show dates of beginning and completion of each major element of construction.

3. Show projected percentages of completion for each item, as of the first day of each month.

4. Indicate the critical path for completion of the entire project.

B. Schedule for Submittals of Shop Drawings, Product Data and Samples.

1. Show the dates for Contractor's submittals.

2. Show the dates reviewed submittals will be required back from the Engineer.

C. Provide sub-schedules to define critical portions of prime schedules.


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SUBMITTAL PROCEDURES 01330-1

SECTION 01330

SUBMITTAL PROCEDURES

P A R T 1 - G E N E R A L

1.1 SUMMARY

A. This Section includes the requirements for submittal procedures associated with the completion of the work under this Contract.

1.2 SUBMITTAL PROCEDURES

A. Contractor shall transmit all submittals in electronic format. Contractor shall submit electronic copy to the ProjectWise site established and maintained by the Engineer. Once submittal has successfully completed the review process, Contractor shall submit electronic copies of the final submittal to the Owner’s Designated Representative (ODR).

B. Contractor shall be responsible for all costs associated with the provision of required electronic submittals, and shall prepare and submit all documents sufficiently in advance of required response time, such that submittal review process does not delay construction progress and schedule.

C. The project ProjectWise site is intended to track and expedite the processing of all submittal-related items to the maximum extent possible. In addition, it is the intent that the project ProjectWise site, in conjunction with email notifications, be used by the Contractor to communicate with the ODR and Engineer throughout the duration of construction, in order to facilitate access to project-related documentation by all parties.

D. ProjectWise Site Software and Hardware Requirements.

1. The Contractor shall purchase any hardware and software that may be required to access the established ProjectWise site via the Internet. The ProjectWise credentials and software download link shall be provided to the Contractor. The license for the first user will be at no cost to the Contractor. Licenses for additional users will be at a cost of $150.00 per user.

2. The Contractor shall provide an adequate number of users to properly manage the project in accordance with the Project Schedule. The Contractor shall have high-speed Internet access through an Internet service provider of his/her choice.

3. Software requirements shall be as follows:

a. Microsoft Windows 7, 64-bit operating system. b. An Internet Browser that supports HTML, Tables, Cookies, JavaScript, and Frames, such as Microsoft Internet Explorer.

4. Hardware requirements shall be as follows:

a. Workstation or laptop of a most-current generation. b. A high-speed connection to the Internet.

E. ProjectWise Site Management and Use.

1. Engineer shall act as the administrator for the project ProjectWise site.


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2. All costs associated with the Contractor’s use of the ProjectWise site, including, but not limited to, computer hardware and Internet service are the responsibility of the Contractor.

3. Each project team member of the Contractor shall have access to the Internet and an Internet e-mail address in order to communicate with various project team members. The Contractor shall provide the names, positions, and e-mail addresses of all project team members designated to receive communications related to the ProjectWise site to the ODR and Engineer at the Pre-Construction Meeting.

F. Communication Process.

1. All project-related submittals and documentation shall also be transferred through the established project ProjectWise site.

2. Electronic submittal documents shall be uploaded in PDF format by the Contractor, and subsequently downloaded by the Engineer and/or ODR for review.

3. Notification of document postings to the ProjectWise site shall be accomplished via email.

4. All documents requiring formal signatures shall be printed, the hard copies signed, scanned, and subsequently uploaded in PDF format to the ProjectWise site for access by all pertinent parties.

5. Engineer shall enter and maintain the official Submittal Log on the project ProjectWise site.

6. Equipment manufacturer field inspection reports, Contractor Daily Reports, Meeting Minutes, Punch Lists, Submittals, and Requests for Information (RFI) shall also be uploaded to the project ProjectWise site in PDF format for downloading, review and comment by all pertinent parties. Support documentation should also be scanned and uploaded to the project ProjectWise site in PDF format for viewing by all team members.

G. The aforementioned project-related communications do not comprise an inclusive list, and are subject to change, supplementation and/or modification in accordance with the direction of the ODR or Engineer.

1.3 SUBMITTAL REQUIREMENTS

A. Accompany each submittal with a dated transmittal letter which includes:

1. Submittal number. Number submittals using technical specification number, followed by sequence number and submission code (i.e., 00000-001-A), all separated by hyphens.

2. Project title and number.

3. The names of:

a. Contractor, include name and resume of project foreman. b. Subcontractor, include names and resumes of project foremen. c. Supplier. d. Manufacturer.

4. Identification of product or material.

5. Relation to adjacent structure or materials.

6. Specification section number and/or drawing number.


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7. Applicable standards, such as ASTM number or Federal Specification.

B. All deviations from plans and specifications shall be provided in written format as an attachment to the transmittal form with reasons, supporting data, and other related information demonstrating that item qualifies as an approved substitution for the specified equipment. Identify all proposed product or system limitations that may be detrimental to successful performance of the completed work. Deviations not listed and discovered post-review shall be grounds for rejection of work.

C. Apply signed Contractor's stamp certifying that review, verification of product requirements, field dimensions, adjacent construction work, and coordination of information, as related to the submittal in question, have occurred. Contractor's stamp, dated and initialed or signed, shall be placed on each submittal item. Any submittal items that do not have the Contractor's stamp shall be returned without review.

D. Whenever possible, post related submittals (ex. pump and associated motor and controls component information) simultaneously to expedite Engineer’s review.

E. Submittals that are not required, and required submittals which do not conform to the requirements of this Section, shall not be reviewed. Receipt of such submittals shall be acknowledged.

F. Alert all parties via email when submittals are uploaded to the project ProjectWise site for review. Alert all impacted Installing Contractors when reviewed submittals are uploaded to project ProjectWise site by Engineer. Instruct parties to promptly report any inability to comply with provisions.

1.4 REQUIRED SUBMITTALS

A. Submit the following items prior to the commencement of construction activities.

1. Schedule of Values.

2. Schedule of Material Values.

3. Construction Schedule(s).

4. Construction Phasing Plan.

5. Water Plant Shutdowns.

6. List of technical and shop drawing submittals.

7. Submittal schedule.

B. During the progress of the work, make the following submittals at the frequency noted below to prevent any delay in the work.

1. Updated Construction Schedules [every one (1) week].

2. Shop Drawings, Product Data and Samples [ALL submittals within seven (7) days of the effective date of the Agreement.].

3. Mill Certificates [ALL certificates within seven (7) days of the effective date of the Agreement].

a. Reinforcing Steel: Section 03210 – Concrete Reinforcement b. Bulk Cement: Section 03310 – Cast-in-Place Concrete c. Steel Pipe: Section 15105 – Pipe and Pipe Fittings and Section 15191 – Gas Piping and Appurtenances


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4. Construction Photographs. Submit with each application for payment. Take two site photos from different directions and a minimum of 10 photos within plant of various structures, interior and exterior piping, buildings and related facilities. Use same vantage points for subsequent photos. Identify photos with date, time, location and project identification. Pay applications will not be processed without photographs.

5. Application for Payment. Submit applications for partial payment as specified in the Contract Conditions and within the time specified in the Agreement. No items would be paid until approved submittals are on file.

6. Material and Equipment List.

C. Allow 14 calendar days for review and approval of each submittal.

D. WITH A WRITTEN NOTICE OF COMPLETION, SUBMIT THE ITEMS IN ACCORDANCE WITH SECTION 01770 AS A CONDITION OF FINAL ACCEPTANCE OF THE WORK.

1.5 RESUBMISSION REQUIREMENTS.

A. In the instance that initial submittal is rejected by Owner or Engineer, revise submittal documents as required and resubmit as specified for initial submittal. Indicate on drawings any changes which have been made, including those requested by the Owner or Engineer.

B. Assign a submittal number that is the same as the original submittal number; however, submission code shall be revised to reflect the appropriate sequential letter suffix, beginning with "B".

C. Engineer shall be responsible for reviewing two (2) submittals related to any one item (original submittal and one resubmittal). If the contractor is required to resubmit shop drawings, catalog cuts, or informational submittals for more than two (2) submittals related to any one item, the Engineer will charge for the review of the submittal at $180.00 per hour to be billed to the Contractor for professional services.

P A R T 2 - P R O D U C T S

Not Used.

P A R T 3 - E X E C U T I O N

3.1 SUBMITTAL SCHEDULE

Due to the limited construction period and compressed schedule, the Contractor shall submit ALL required submittals within seven (7) days of the effective date of the Agreement.

END OF SECTION


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01325-2

1.5 PROGRESS REVISIONS

A. Indicate progress of each activity to date of submission.

B. Show changes occurring since previous submission of schedule.

1. Major changes in scope.

2. Activities modified since previous submission.

3. Revised projections in progress and completion.

4. Other identifiable changes.

C. Provide a narrative report as needed to define:

1. Problem areas, anticipated delays and the impact on schedule.

2. Corrective action that will be taken by the Contractor to get the project back on schedule. This item is required whenever the progress of the job is behind the original progress schedule.

3. The effect of changes on schedules or on other prime contractors.

1.6 SUBMITTALS

A. Submit initial schedules to Engineer for review and approval prior to the commencement of construction activities. If required, Contractor shall resubmit schedules within seven (7) days after return of initial review copy.

B. Submit revised progress schedules with each application for payment.

1.7 DISTRIBUTION

A. Distribute copies of reviewed documents to concerned parties.

B. Instruct recipients to report promptly to Contractor, in writing, any problems anticipated by the projections shown in the schedules.

PART 2 - PRODUCTS

Not used.

PART 3 - EXECUTION

Not used.

END OF SECTION


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SHOP DRAWINGS, PRODUCT DATA AND SAMPLES 01340-1

SECTION 01340

SHOP DRAWINGS, PRODUCT DATA AND SAMPLES

PART 1 - GENERAL

1.1 SUMMARY

This Section includes the requirements for shop drawings, product data and samples to be submitted by the Contractor under the conditions of the Contract.


A. Section 01330 - Submittal Procedures.

B. Section 01325 - Construction Schedules.

C. Section 01600 - Materials and Equipment.

D. Section 01781 - Project Record Documents.

1.3 SHOP DRAWINGS

A. Submit shop drawings, product data and samples for each item on or before the date identified in the Submittal Schedule, as required by Section 01330 – Submittal Procedures. Shop drawings which are not required will not be reviewed.

B. Preparation by a qualified detailer is required.

C. Where necessary for clarity, identify details by reference to sheet and detail numbers, schedule or room numbers as shown on the Contract Drawings.

D. Field dimensions shall be clearly indicated as such.

E. Prepare an electronic PDF copy of each shop drawing.

F. Reproduction Note. The use of reproductions of the Contract Drawings by any contractor, subcontractor, erector, fabricator or material supplier, in lieu of shop drawing preparation will be permitted. However, it will signify such party’s acceptance of all information shown therein as correct, and obligates him to any job expense, real or implied, arising due to any errors that may occur thereon. In addition, all references to the Architect or Engineer, including all professional seals, are to be removed should the Contract Drawings be used as shop drawings.

1.4 PRODUCT DATA

A. Modify the manufacturer's standard schematic drawings to delete or supplement information as applicable.

B. For manufacturer's catalog sheets, brochures, diagrams, schedules, performance charts, illustrations and other descriptive data:

1. Clearly mark each copy to identify materials, products or models which are being submitted for review.

2. Show dimensions and clearances required.

3. Show performance characteristics and capacities.


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4. Show wiring diagrams and controls.

1.5 SAMPLES

A. Submit samples of sufficient size and quantity to clearly illustrate functional characteristics of product or materials including integrally related parts and attachment devices, and full range of available colors.

B. Erect field samples and mock-ups at the project site in an acceptable location. Construct each sample complete, including work of all trades required in finished work.

C. Submit two samples unless greater quantity is specified in the respective technical specification section. One sample will be retained unless noted otherwise.

1.6 SUBMISSION REQUIREMENTS

A. Accompany each submittal with a dated transmittal letter which includes:

1. Submittal number. Number submittals sequentially beginning with "001".


3. The names of:

a. Contractor.

b. Subcontractor.

c. Supplier.

d. Manufacturer.

4. Identification of product or material.

5. Relation to adjacent structure or materials.

6. Specification section number and/or drawing number.

7. Applicable standards, such as ASTM number or Federal Specification.

8. Identification of deviations from the Contract Documents. List all deviations from the Contract Documents on a separate sheet detailing the reasons for deviation.

B. Provide a blank space on each shop drawing, approximately 5" by 5", for the Engineer's stamp.

C. Contractor's stamp, dated and initialed or signed, certifying review of submittal, verification of field measurements and compliance with Contract Documents shall be placed on each submittal item. Any submittal items that do not have the Contractor's stamp will be returned without review.

D. Insofar as practical, make all submittals for each of the following categories at one time.

1. Mechanical.

2. Structural.

3. Electrical.

4. Instrumentation

5. Equipment; submit all components of a system together.


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1.7 ENGINEER'S DUTIES

A. Review and return submittals within 30 calendar days after receipt.

B. Review for conformance with the design intent and with the Contract Documents.

C. Affix stamp and initials or signature, and indicate approved or requirements for re-submittal.

D. Return submittals to Contractor for distribution or for resubmission.

1.8 RESUBMISSION REQUIREMENTS

A. Assign a submittal number that is the same as the original submittal number plus a sequential letter suffix beginning with "A".

B. Revise documents as required and resubmit as specified for initial submittal. Indicate on drawings any changes which have been made, including those requested by the Engineer.

C. The Engineer shall be responsible for reviewing only three submittals on any one item (original submittal plus two re-submittals). The Contractor shall compensate the Engineer for any review of re-submittals beyond this number at $140 per hour.

1.9 DEVIATIONS AND SUBSTITUTIONS

All deviations from plans and specifications shall be listed as an attachment to the transmittal form with reasons, supporting data, and other related information demonstrating that item qualifies as an approved substitution for the specified equipment. Deviations not listed and discovered post-review will be grounds for rejection of work.

PART 2 - PRODUCTS

Products which require shop drawings, product data and samples are indicated in the individual technical specification sections.

PART 3 - EXECUTION

Not used.

END OF SECTION


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BLANK PAGE


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QUALITY CONTROL

01380-1

SECTION 01380

QUALITY CONTROL

PART 1 - GENERAL

1.1 SECTION INCLUDES

A. Quality assurance and control of installation.

B. References.

C. Field Samples.

D. Inspections and testing laboratory services.

E. WORK INCLUDED

F. Manufacturer’s field services and reports.


A. Section 01330 – Submittal Procedures.

B. Section 01600 – Materials and Equipment.

1.3 QUALITY ASSURANCE/CONTROL OF INSTALLATION

A. Monitor quality control over suppliers, manufacturers, products, services, site conditions, and workmanship, to produce Work of specified quality.

B. Comply fully with manufacturers' instructions, including each step in sequence.

C. Should manufacturers' instructions conflict with Contract Documents, request clarification from Engineer before proceeding.

D. Comply with specified standards as a minimum quality for the Work except when more stringent tolerances, codes, or specified requirements indicate higher standards or more precise workmanship.

E. Perform Work by persons qualified to produce workmanship of specified quality.

F. Secure products in place with positive anchorage devices designed and sized to withstand stresses, vibration, physical distortion or disfigurement.

1.4 REFERENCES

A. Conform to the reference standards by date of Contract Documents.

B. Specific provisions of codes, regulations and standards may be referenced in individual Specifications to assist the Contractor and identify options selected by the Engineer. Such references do not relieve the Contractor from compliance with other applicable provisions of the codes, regulations and standards not specifically referenced.

C. Should specified reference standards conflict with Contract Documents, request clarification from Engineer before proceeding.


WATER PLANTS

QUALITY CONTROL

01380-2

1.5 FIELD SAMPLES

A. Install field samples at the site as required by individual Specification Sections for review.

B. Acceptable samples represent a quality level for the Work.

C. Where field sample is specified in individual Specification Sections to be removed, clear area after field sample has been accepted by Engineer.

1.6 INSPECTION AND TESTING LABORATORY SERVICES

A. The Contractor shall employ and pay for services of independent testing firms acceptable to the Owner to perform inspection and testing as required by the Engineer, and where such independent testing is specifically required to be performed by the Contract Documents. Acceptable testing firms shall be one of the following:

1. Terracaon Attn: Dennis Henley

11133 I-45 North Conroe, Texas 77302

(936) 539-1384 2. HTS, Inc. Consultants Attn: Freddie Brooks Jr. 416 Pickering St . Houston, Tx 77091 (713) 692-8373

B. Reports shall be submitted by the independent firm to the Engineer, in duplicate, indicating observations and results of tests and indicating compliance or non-compliance with Contract Documents.

C. The independent firm shall perform inspections, tests, and other services specified in individual Specification Sections and as required by the Engineer.

D. The Contractor shall cooperate with all inspection and testing firms; furnish samples of materials, design mix, equipment, tools, storage and assistance as requested by the Engineer. The Contractor shall notify the Engineer and testing firm at least 48 hours (or as otherwise specified) prior to the expected time for operations requiring such services.

E. Retesting required because of non-conformance to specified requirements shall be performed by the same independent firm on instructions by the Engineer. Contractor shall be responsible for all retesting expenses.

1.7 WORK INCLUDED

A. Testing is required for the following items of work:

1. Soils compaction control.

2. Portland cement concrete paving.

3. Crushed stone pavement.

4. Concrete reinforcement.

5. Cast in place concrete.


WATER PLANTS

QUALITY CONTROL

01380-3

6. Precast, prestressed concrete.

7. Mortar.

1.8 MANUFACTURER'S FIELD SERVICES AND REPORTS

A. Submit qualifications of qualified field service personnel to Engineer for approval 30 days in advance of required testing or observations.

B. When specified in individual Specification Sections, where field condition requires material or product suppliers or manufacturers to provide qualified staff personnel to observe site conditions, conditions of surfaces and installation, quality of workmanship, start-up of equipment, test, adjust, and balance of equipment as applicable, and to initiate instructions when necessary, a manufacturer's representative shall be provided at Contractor's expense.

C. Manufacturer must report observations and site decisions or instructions given to applicators or installers that are supplemental or contrary to manufacturer's written instructions.

D. The manufacturer's representative shall certify the materials and/or equipment supplied by him has been properly installed and is functioning correctly.

E. Submit report in duplicate within thirty (30) days of observation to Engineer for review.

PART 2 - PRODUCTS

Not Used.

PART 3 - EXECUTION

Not used.

END OF SECTION


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QUALITY CONTROL

01380-4

BLANK PAGE


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REFERENCE STANDARDS

01400-1

SECTION 01400

REFERENCE STANDARDS

PART 1 - GENERAL

1.1 QUALITY ASSURANCE

A. For work specified by association, trade of Federal Standards, follow requirements of the standard to the extent referenced, except when more rigid requirements are specified or are required by applicable codes or by Contract Documents.

B. Follow reference standard effective 60 days prior to date of Project Manual.

AA Aluminum Association

1525 Wilson Blvd., Suite 600 Arlington, VA 22209 (703) 358-2960 www.aluminum.org

AABC Associated Air Balance Council

1518 K Street, NW Washington, DC 20005 (202) 737-0202 www.aabchq.com

AAMA American Architectural Mfrs Assn. 1827 Walden Office Sq., Suite 550

Schaumberg, IL 60173-4268 (847) 303-5664 www.aamanet.org

AASHTO American Assn. of State Hwy. & Transportation Officials 444 North Capitol Street, NW, Suite 249

Washington, DC 20001 (202) 624-5800 www.transportation.org

ACI American Concrete Institute PO Box 9094

Farmington Hills, MI 48333-9094

(248) 848-3700 www.concrete.org AEIC Assn. of Edison Illuminating Cos. PO Box 2641 Birmingham, AL 35291-0992 (205) 257-2530

www.aeic.org AGC Associated General Contractors of

America 2300 Wilson Blvd., Suite 400 Arlington, VA 22201 (703) 548-3118 www.agc.org AGMA American Gear Manufacturers Assn. 1001 N. Fairfax Street, Fifth Floor Alexandria, VA 22314-1587 (703) 684-0211 www.agma.org AHA American Hardboard Assn. 1210 W. Northwest Hwy. Palatine, IL 60067 (847) 934-8800 domensino.com/AHA


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REFERENCE STANDARDS

01400-2

AHRI Air-Conditioning, Heating, & Refrigeration Institute

2111 Wilson Blvd., Suite 500 Arlington, VA 22201 (703) 524-8800 www.ahrinet.org AI Asphalt Institute 2696 Research Park Drive Lexington, KY 40511-8480 (859) 288-4960 www.asphaltinstitute.org AIA American Institute of Architects 1735 New York Avenue, NW Washington, DC 20006-5292 (800) 242-3837 www.aia.org AISC American Institute of Steel

Construction 1 E. Wacker Drive, Suite 700 Chicago, IL 60601-1802 (312) 670-2400 www.aisc.org AISI American Iron & Steel Institute 1140 Connecticut Ave., NW Suite 705 Washington, DC 20036 (202) 452-7100 www.steel.org AITC American Institute of Timber

Construction 7012 S. Revere Parkway, Suite 140 Centennial, CO 80112 (303) 792-9559 www.aitc-glulam.org AMCA Air Movement & Control Assn. Intl.,

Inc. 30 West University Drive Arlington Heights, IL 60004-1806 (847) 394-0150 www.amca.org

ANSI American Natl. Stds. Institute 25 W. 43rd Street, 4th Floor New York, NY 10036 (212) 642-4900 www.ansi.org APA APA - The Engineered Wood Assn. (formerly American Plywood Assn.) 7011 S. 19th Tacoma, WA 98466 (253) 565-6600 www.apawood.org API American Petroleum Institute 1220 L Street, NW Washington, DC 20005-4070 (202) 682-8000 www.api.org AREMA American Railway Engrg. & Maintenance-of-Way Assn. 10003 Derekwood Lane, Suite 210 Lanham, MD 20706 (301) 459-3200 www.arema.org ASHRAE American Soc. of Heating, Refrig. &

Air Conditioning Engrs, Inc. 1791 Tullie Circle, NE Atlanta, GA 30329 (800) 527-4723 www.ashrae.org ASME American Soc. of Mech. Engrs. 3 Park Avenue New York, NY 10016-5990 (800) 843-2763 www.asme.org ASTM ASTM International (formerly American Society for

Testing & Materials) PO Box C700 100 Bar Harbor Drive W. Conshohocken, PA 19428-2959 (610) 832-9500 www.astm.org


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REFERENCE STANDARDS

01400-3

AWI Architectural Woodwork Institute 46179 Westlake Drive, Suite 120 Potomac Falls, VA 20165 (571) 323-3636 www.awinet.org AWPA American Wood Protection Assn. (formerly American Wood

Preservers’ Assn.) PO Box 361784 Birmingham, AL 35236-1784 (205) 733-4077 www.awpa.com AWPI American Wood-Preservers’ Inst. 2750 Prosperity Ave., Suite 550 Fairfax, VA 22031-4312 (800) 356-AWPI www.awpi.org AWS American Welding Society 550 N.W. LeJeune Road Miami, FL 33126 (800) 443-9353 www.aws.org AWWA American Water Works Assn. 6666 West Quincy Avenue Denver, CO 80235 (800) 926-7337 www.awwa.org BHMA Builders' Hardware Mfrs. Assn. 355 Lexington Ave., 15th Floor New York, NY 10017 (212) 297-2122 www.buildershardware.com BIA Brick Industry Association 1850 Centennial Park Dr., Ste 301 Reston, VA 20191 (703) 620-0010 www.gobrick.com CFR Code of Federal Regulations U.S. Government Printing Office Mail Stop IDCC 732 N. Capitol Street, NW Washington, DC 20401 (866) 512-1800 www.gpoaccess.gov

CGA Compressed Gas Association 4221 Walney Road, 5th Floor Chantilly, VA 20151-2923 (703) 788-2700 www.cganet.com CLFMI Chain Link Fence Mfrs. Institute 10015 Old Columbia Rd., Ste B-215 Columbia, MD 21046 (410) 290-6267 www.chainlinkinfo.org CRSI Concrete Reinforcing Steel Inst. 933 N. Plum Grove Road Schaumburg, IL 60173-4758 (847) 517-1200 www.crsi.org CTI Cooling Technology Institute PO Box 73383 Houston, TX 77273-3383 (281) 583-4087 www.cti.org DHI Door and Hardware Institute 14150 Newbrook Drive, Suite 200 Chantilly, VA 20151 (703) 222-2010 www.dhi.org EIA Environmental Information Assn. 6935 Wisconsin Ave., Suite 306 Chevy Chase, MD 20815-6112 (301) 961-4999 www.eia-usa.org EJMA Expansion Joint Mfrs. Assn. 25 N. Broadway Tarrytown, NY 10591 (914) 332-0040 www.ejma.org EPA Environmental Protection Agency Ariel Rios Building 1200 Pennsylvania Ave., NW Washington, DC 20460 www.epa.gov


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REFERENCE STANDARDS

01400-4

FAA Federal Aviation Administration 800 Independence Ave., SW Washington, DC 20591 (866) 835-5322 www.faa.gov FM Factory Mutual Research Corp. 1151 Boston-Providence Turnpike Norwood, MA 02062 (781) 762-4300 www.fmglobal.com FS Federal Standardization Documents General Services Administration Specifications Unit (WFSIS) 7th and D Streets, SW Washington, DC 20407 (203) 472-2205 www.gsa.gov GANA Glass Assn. of North America 800 SW Jackson Street, Ste 1500 Topeka, KS 66612-1200 (785) 271-0208 www.glasswebsite.com IAPMO International Assn. of Plbg. & Mech.

Officials 4755 E. Philadelphia St. Ontario, CA 91761 (909) 472-4100 www.iapmo.org ICEA Insulated Cable Engineers Assn. PO Box 1568 Carrollton, GA 30112 www.icea.net IEEE Inst. of Electrical & Electronics

Engineers 445 Hoes Lane Piscataway, NJ 08854-4141 (800) 678-4333 www.ieee.org

ISA International Society of Automation (formerly The Instrumentation,

Systems & Automation Society) 67 Alexander Drive Research Triangle Park, NC 27709 (919) 549-8411 www.isa.org ISO International Organization for

Standardization 1, ch. de la Voie-Creuse, CP 56 CH-211 Geneva 20, Switzerland 41-22-749-01-11 www.iso.org MIL Military Standardization Documents

(U.S. Dept of Defense) Document Automation & Production

Service Bldg. 4/D, 700 Robbins Ave. Philadelphia, PA 19111-5094 (877) 327-7226 dodssp.daps.dla.mil MSS Mfrs. Standardization Society of the

Valve & Fittings Industry 127 Park Street, NE Vienna, VA 22180 (703) 281-6613 www.mss-hq.org NAAMM Natl. Assn. of Arch. Metal Mfrs. 800 Roosevelt Road Bldg. C, Suite 312 Glen Ellyn, IL 60137 (630) 942-6591 www.naamm.org NACE NACE International (formerly Natl. Assn. of Corrosion

Engrs.) 1440 South Creek Drive Houston, TX 77084-4906 (281) 228-6200 www.nace.org


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REFERENCE STANDARDS

01400-5

NAIMA North American Insulation Manufacturers Assn.

44 Canal Center Plaza, Suite 310 Alexandria, VA 22314 (703) 684-0084 www.naima.org NCMA Natl. Concrete Masonry Assn. 13750 Sunrise Valley Drive Herndon, VA 20171-4662 (703) 713-1900 www.ncma.org NEC National Electrical Code (see NFPA) www.necplus.org NEMA National Electrical Mfrs. Assn. 1300 N. 17th Street, Suite 1752 Rosslyn, VA 22209 (703) 841-3200 www.nema.org NESC National Electrical Safety Code www.standards.ieee.org/nesc NFPA National Fire Protection Assn. 1 Batterymarch Park Quincy, MA 02169 (800) 344-3555 www.nfpa.org NIST Natl. Inst. of Standards & Tech. 100 Bureau Dr., Stop 1070 Gaithersburg, MD 20899-1070 (301) 975-6478 www.nist.gov NRCA Natl. Roofing Contractors Assn. 10255 West Higgins Rd., Suite 600 Rosemont, IL 60018-5607 (847) 299-9070 www.nrca.net

NRMCA Natl. Ready Mixed Concrete Assn. 900 Spring Street Silver Spring, MD 20910 (888) 846-7622 www.nrmca.org NSF NSF International (formerly National Sanitation

Foundation PO Box 130140 789 N. Dixboro Road Ann Arbor, MI 48113-0140 (800) 673-6275 www.nsf.org NTMA National Terrazzo & Mosaic Assn. PO Box 2605 Fredericksburg, TX 78624 (800) 323-9736 www.ntma.com OSHA Occupational Safety & Health Administration 200 Constitution Ave., NW Washington, DC 20210 (800) 321-6742 www.osha.gov PCA Portland Cement Association 5420 Old Orchard Road Skokie, IL 60077 (847) 966-6200 www.cement.org PCI Precast/Prestressed Concrete Inst. 200 W. Adams St.., # 2100 Chicago, IL 60606-6938 (312) 786-0300 www.pci.org PDI Plumbing & Drainage Institute 800 Turnpike Street, Suite 300 North Andover, MA 01845 (800) 589-8956 www.pdionline.org


WATER PLANTS

REFERENCE STANDARDS

01400-6

PIMA Polyisocyanurate Insulation Manufacturers Assn.

7315 Wisconsin Ave., Ste 400E Bethesda, MD 20814 (301) 654-0000 www.pima.org PPI Plastics Pipe Institute 105 Decker Court, Suite 825 Irving, TX 75062 (469) 499-1044 www.plasticpipe.org RCSC Research Council on Structural

Connections www.boltcouncil.org RMA Rubber Manufacturers Assn. 1400 K St., NW, Suite 900 Washington, DC 20005 (202) 682-4800 www.rma.org SDI Steel Deck Institute PO Box 25 Fox River Grove, IL 60021 (847) 458-4647 www.sdi.org SDI Steel Door Institute 30200 Detroit Road Westlake, OH 44145 (440) 899-0010 www.steeldoor.org SIGMA Sealed Insulating Glass

Manufacturers Association 401 N. Michigan Ave., Suite 2400 Chicago, IL 60611 (312) 644-6610 www.sigmaonline.org SJI Steel Joist Institute 1173B London Links Drive Forest, VA 24551 (434) 525-7377 www.steeljoist.org

SMACNA Sheet Metal & Air Conditioning Contractors’ National Assn.

4201 Lafayette Center Dr. Chantilly, VA 20151-1219 (703) 803-2980 www.smacna.org SPIB Southern Pine Inspection Bureau PO Box 10915 Pensacola, FL 32524-0915 (850) 434-2611 www.spib.org SSPC The Society for Protective Coatings 40 24th St., Sixth Floor Pittsburgh, PA 15222-4656 (877) 281-7772 www.sspc.org

STI/SPFA Steel Tank Institute/Steel Plate Fabricators Assn.

570 Oakwood Road Lake Zurich, IL 60047 (847) 438-8265 www.steeltank.com TAS Texas Accessibility Standards Texas Dept. of Licensing &

Regulation PO Box 12157 Austin, TX 78711 (800) 803-9202

www.license.state.tx.us/ab/ abtas.htm TCNA Tile Council of North America 100 Clemson Research Blvd. Anderson, SC 29625 (864) 646-8453 www.tileusa.com TCEQ Texas Commission on Environ-

mental Quality PO Box 13087 Austin, TX 78711-3087 (512) 239-1000 www.tceq.state.tx.us


WATER PLANTS

REFERENCE STANDARDS

01400-7

TxDOT Texas Department of Transportation 125 E. 11th Street Austin, TX 78701 (512) 463-8585 www.dot.state.tx.us UL Underwriters’ Laboratories, Inc. 2600 N.W. Lake Road Camas, WA 98607-8542 (877) 854-3577 www.ul.com UNI-BELL UNI-BELL PVC Pipe Association 2711 LBJ Freeway, Suite 1000 Dallas, TX 75234 (972) 243-3902 www.uni-bell.org

WCLIB West Coast Lumber Inspection Bureau

P.O. Box 23145 Portland, OR 97281 (503) 639-0651 www.wclib.org WDMA Window & Door Mfrs. Assn. 401 N. Michigan Ave., Suite 2200 Chicago, IL 60611 (312) 321-6802 www.wdma.com WWPA Western Wood Products Assn. 522 SW 5th Avenue, Suite 500 Portland, OR 97204-2122 (503) 224-3930 www2.wwpa.com

1.2 PARTIAL LIST OF PHRASES

A. Read “includes” and “including” as having the phrase “but not necessarily limited to” immediately following the words, if not otherwise written out.

B. “Required” means products, labor and services provided by the Contractor to properly complete the Work following the Contract Documents and the design concept expressed therein, such required work being determined and governed by field or shop conditions.

PART 2 - PRODUCTS

Not Used

PART 3 - EXECUTION

Not Used

END OF SECTION


WATER PLANTS

REFERENCE STANDARDS

01400-8

BLANK PAGE


WATER PLANTS

CONSTRUCTION FACILITIES AND TEMPORARY CONTROLS

01500-1

SECTION 01500


PART 1 - GENERAL


A. Temporary Utilities: Electricity, lighting, heat, ventilation, telephone service, water, and sanitary facilities.

B. Temporary Controls: Barriers, fencing, protection of the Work, and water control.

C. Construction Facilities: Access roads, parking, traffic regulation, field offices, removal of Utilities, Facilities and Controls and Dust or Fume Containment Control System.

1.2 TEMPORARY UTILITIES

A. Provide, maintain and pay for temporary utilities (electricity, lighting, heat, ventilation, and telephone service). The Owner will provide free water for use by the Contractor, but the Contractor must set up a billing account so that Owner can monitor and account for usage.

B. The temporary services shall conform to applicable codes, regulations, standards and field requirements.

1.3 TEMPORARY SANITARY FACILITIES

A. Provide, maintain and pay for required facilities and enclosures.

1.4 BARRIERS, FENCING AND PROTECTION OF THE WORK

A. Provide, maintain and pay for barriers, fencing and protection of the Work.

B. Provide barriers and/or fencing to prevent unauthorized entry to construction areas, to allow for Owner's use of site, and to protect existing facilities and adjacent properties from damage from construction operations.

C. Provide protection for plant life designated to remain. Replace damaged plant life.

D. Protect installed Work and provide special protection where specified in individual Specification Sections.

1.5 WATER AND EROSION CONTROL

A. Provide, maintain and pay for water control system for the Work.

B. Grade site to drain. Maintain excavations free of water. Provide, operate, and maintain pumping equipment.

C. Protect site from puddling or running water. Provide water barriers as required to protect site from soil erosion.

D. Erosion control methods shall be used to prevent siltation to lands and waterways adjoining construction area. The erosion control methods shall include but not be limited to siltation fences, trench stabilization and immediate mulching and seeding.

E. Conform to all applicable codes.


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01500-2

1.6 ACCESS ROADS, PARKING AND TRAFFIC REGULATION

A. Provide, maintain and pay for access roads, traffic and parking for the Work.

B. Backfill and close trenches within 24-hours to maintain site access. Provide necessary equipment, steel plating, or other temporary surface as needed to maintain site access.

C. In the case of an emergency, the Contractor shall work diligently and continuously, provide all necessary equipment and materials, and assist Owner to restore site access so that emergency vehicles have unhindered ingress and egress to the site.

D. Construct and maintain temporary roads accessing public thoroughfares to serve construction area.

E. Extend and relocate as Work progress requires.

F. Provide and maintain access to fire hydrants, free of obstructions.

G. Provide and maintain means of removing mud from vehicle wheels before entering public streets.

H. On-site roads that may be used for construction traffic shall be designated by the Engineer at the preconstruction meeting.

I. Provide temporary surface parking areas to accommodate construction personnel.

J. When site space is not adequate, provide additional off-site parking.

K. Designate three parking spaces for use by the Owner and Engineer.

L. Where necessary, signs, barricades, lights and traffic control devices and usage shall comply with the requirements of the U.S Department of Transportation Federal Highway Administration, manual on Uniform Traffic Control Devices, Millennium Edition and its addenda, except where specifically super ceded by 29 CFR 1926, 200-202. At least one lane of traffic in each direction shall be maintained, except where specifically approved in writing by the appropriate municipality or agency. Appropriate sketches showing type and placement of traffic control devices shall be prepared by the Contractor for review and approval by the governing municipality.

1.7 CONTRACTOR'S AND ENGINEER'S FIELD OFFICES

A. Contractor's Office

1. The Contractor shall provide and maintain one (1) clean, weather-tight office at an approved location during the period of construction at which Contractor or its authorized agent shall be present, or to which either may be called at all times while the Work is in progress. Copies of all permits, the Contract Documents and reviewed shop drawings for the Work shall be kept at said office ready for use and reference at any time. Said office shall be maintained by the Contractor until final payment for the Work, and then removed from site, unless the Owner orders earlier removal.

2. The Contractor shall have a telephone installed in its field office as soon as possible. All expenses in connection with the Contractor's Field Office shall be paid by the Contractor.


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01500-3

1.8 REMOVAL OF UTILITIES, FACILITIES AND CONTROLS

A. Contractor shall remove all temporary utilities, sanitary facilities, barriers, fencing, water control and other facilities prior to application for final payment.

B. Clean and repair damage caused by installation or use of temporary Work.

C. Restore existing facilities used during construction to original condition. Restore permanent facilities used during construction to specified condition.

1.9 PROGRESS CLEANING

A. Maintain areas free of waste materials, debris, and rubbish. Maintain site in a clean and orderly condition.

B. Remove debris and rubbish from pipe chases, plenums, attics, crawl spaces, and other closed or remote spaces, prior to enclosing the space.

C. Broom and vacuum clean interior areas prior to start of surface finishing, and continue cleaning to eliminate dust.

D. Remove waste materials, debris, and rubbish from site daily to waste material storage area. Periodically, as required and dispose of waste material off-site.

1.10 DUST OR FUME CONTAINMENT SYSTEM

A. The Contractor shall prepare and submit a plan for a dust and fume containment system that shall:

1. Protect owner’s personnel and existing equipment.

2. Warn personnel of containment area.

3. Provide an external air source to the 100% contained area with impervious tarps and exhaust air through a High Efficiency Particulate Air Filter (HEPA).

4. Replace or clean filter daily.

B. Existing or proposed equipment shall not be exposed to any dust or fumes.

C. The Contractor shall provide supply and exhaust air ducts, mechanical ventilation and HEPA Air Filter.

PART 2 - PRODUCTS

Not Used.

PART 3 - EXECUTION

Not used.

END OF SECTION


WATER PLANTS


01500-4

BLANK PAGE


WATER PLANTS

MATERIALS AND EQUIPMENT

01600-1

SECTION 01600 MATERIALS AND EQUIPMENT

PART 1 - GENERAL


A. Products.

B. Transportation and handling.

C. Storage and protection.

D. Product options.

E. Substitutions.

F. Alternates.

1.2 RELATED SECTIONS

A. Section 01380 - Quality Control.

1.3 PRODUCTS

A. Products: Means new material, machinery, components, equipment, fixtures, and systems forming the Work. Does not include machinery and equipment used for preparation, fabrication, conveying and erection of the Work. Products may also include existing materials or components required for reuse.

B. Product Quality: All materials, equipment and supplies incorporated into the Work shall be new, undamaged and shall be the best of their respective kinds for their intended use. All materials, equipment and supplies not otherwise described shall be of the best quality, and should any workmanship or materials, equipment or supplies be needed that are not directly or indirectly set forth in the Contract Documents, but are nevertheless necessary to the proper execution according to the obvious intent thereof, the Contractor shall understand the same to be implied and shall provide for it in Contractor's tender as fully as if it were particularly described.

C. Standard Specifications: Reference to standard specifications of any technical society, organization, or association, or to codes of local, state or federal authorities, shall mean the latest standard, code, specification, or tentative specification adopted and published at the date of taking bids, unless specifically stated otherwise.

All design, workmanship, and materials, equipment and supplies shall comply with the latest revisions of all applicable laws, codes, standards, and other legal requirements having jurisdiction in the area in which the Work is executed, and with all applicable manuals of practice including where applicable, but not limited to the following:

1. American Water Works Association - AWWA

2. American Standards Association - ASA

3. American Society for Testing and Materials - ASTM


WATER PLANTS


01600-2

4. American Association of State Highway and Transportation Officials - AASHTO

5. National Electrical Code - NEC

6. American National Standards Institute - ANSI

7. Institute of Electrical & Electronic Engineers - IEEE

8. Underwriters' Laboratories - UL

9. National Electrical Manufacturers' Association - NEMA

10. American Society of Heating, Refrigeration and

11. Air Conditioning Engineers - ASHRAE

12. American Gear Manufacturers' Association – AGMA

13. American Society of Lubricating Engineers - ASLE

14. American Society of Mechanical Engineers - ASME

15. American Welding Society - AWS

16. Chlorine Institute - CI

17. Diesel Engine Manufacturers' Association – DEMA

18. Electronic Industries Association - EIA

19. Factory Mutual System - FM

20. Illuminating Engineering Society of North America - IES

21. Instrument Society of America - ISA

22. Prestressed Concrete Institute - PCI

23. Plastic Pipe Institute - PPI

24. American Society of Civil Engineers - ASCE

25. U.S. Steel Wire, Washburn and Moen, American Steel and Wire or Roebling Gauge - Stl. WG

26. Outside Screw and Yoke - OS&Y

27. Working Steam Pressure - WSP

28. United States Standard Gauge - USS Gauge

29. American or Brown and Sharpe Wire Gauge - AWG

30. Federal Specifications Issued by the Federal Supply Service of the General Services Administration, Washington, D.C. - Fed. Spec.

31. National Pipe Thread - NPT

32. Water, Oil, Gas - WOG

33. Texas Department of Transportation - TxDOT

34. Society for Protective Coatings - SSPC


WATER PLANTS


01600-3

35. National Fire Protection Association - NFPA

36. American Concrete Institute - ACI

37. Portland Cement Association - PCA

38. American Institute of Steel Construction - AISC

39. Concrete Reinforcing Steel Institute - CRSI

40. Occupational Safety and Health Act - OSHA

41. Sheet Metal and Air Conditioning Contractor's National Assoc., Inc. - SMACNA

D. Prior Experience of Manufacturer: All materials, equipment or supplies bid upon or furnished under this Contract shall be the product of a manufacturer who is experienced in the design and construction of such materials, equipment, or supplies and who has furnished similar materials, equipment or supplies that, in the opinion of the Engineer, has been in satisfactory operation for a sufficient period of time (minimum 5 years) to establish its reliability.

E. Materials, equipment or supplies that do not meet the experience requirement but that meet all technical requirements, will be considered if the Contractor obtains for the Owner a commitment from the supplier or manufacturer to replace any materials, equipment or supplies in the event of failure within five (5) years from the date of final payment, or such longer period as set forth in the Specifications or the General Conditions, together with a cash deposit or suitable bond acceptable to the Owner to guarantee such commitment.

F. If requested by the Owner or Engineer, the Contractor shall furnish a complete list of all installations (minimum five (5) years) of materials, equipment or supplies Contractor submits for approval under this Contract. The list shall include the names and addresses of both the design engineer and owner and the specific design features requested by the Engineer.

G. Design Life: All materials, equipment or supplies shall be of robust construction and best quality, conservatively rated as to durability rating and design life. Unless otherwise specifically stated in the equipment specification, equipment shall be for municipal service with a minimum design life of 20 years. All parts subject to wear and normal replacement with use shall have a service life comparable to that of the equipment supplied.

The equipment manufacturer shall certify that all items of equipment are conservatively rated for a minimum design life of twenty (20) years as defined by rating and specifying authorities or accepted trade standards.

1.4 TRANSPORTATION AND HANDLING

A. Transport and handle Products in accordance with manufacturer's instructions.

B. Promptly inspect shipments to assure that Products comply with requirements, quantities are correct, and Products are undamaged.

C. Provide equipment and personnel to handle Products by methods to prevent soiling, disfigurement, or damage.


WATER PLANTS


01600-4

1.5 STORAGE AND PROTECTION

A. Store and protect Products in accordance with manufacturer's instructions, with seals and labels intact and legible. Store sensitive Products in weather tight, climate-controlled enclosures.

B. For exterior storage of fabricated Products, place on sloped supports, above ground.

C. Provide off-site storage and protection when site does not permit on-site storage or protection.

D. Cover Products subject to deterioration with impervious sheet covering. Provide ventilation to avoid condensation.

E. Store loose granular materials on solid flat surfaces in a well-drained area. Prevent mixing with foreign matter.

F. Provide equipment and personnel to store Products by methods to prevent soiling, disfigurement, or damage.

G. Arrange storage of Products to permit access for inspection. Periodically inspect to assure Products are undamaged and are maintained under specified conditions.

H. All equipment, materials, and supplies shall be stored at sites within the City of Conroe’s corporate limits to allow for inspection by the Owner and Engineer. The Contractor shall obtain sites as Contractor deems necessary for the storage of equipment, materials and supplies.

I. In the event any on-site storage of equipment, materials and supplies is authorized by the Engineer, in its absolute and sole discretion, all materials, equipment, and supplies authorized for on-site storage shall be placed so as not to injure any part of the Work or existing facilities and so that free access can be had at all times to all parts of the Work and to all public utility installations in the vicinity of the Work. Materials, equipment and supplies authorized for on-site storage shall be kept neatly piled and compactly stored in such locations as will cause a minimum of inconvenience to public travel and adjoining owners, tenants and occupants.

1.6 PROTECTION OF MATERIALS AND EQUIPMENT

A. The Contractor shall store all materials, equipment and supplies as stated in the Specifications. If there is no Specification for storage, the Contractor shall advise all suppliers of the method, conditions, anticipated duration and time of year proposed for storage of their products. If any supplier does not agree with the Contractor's proposed methods of storage, the Contractor shall make all necessary changes to satisfy the supplier. The Contractor shall advise all suppliers in writing that a lack of response on their part to the Contractor's proposed method of storage for materials, equipment, and supplies constitutes their approval of Contractor's proposed method of storage.

1.7 PRODUCT OPTIONS

A. Products Specified by Reference Standards or by Description Only: Any Product meeting those standards or description.


WATER PLANTS


01600-5

B. Products Specified by Naming One or More Manufacturers: Products to manufacturers named and meeting specifications, no options or substitutions allowed.

C. Products Specified by Naming One or More Manufacturers with a Provision for Substitutions: Submit a request for substitution for any manufacturer not named.

1.8 SUBSTITUTIONS

A. Engineer will consider requests for Substitutions only within 30 days after date of Owner-Contractor Agreement.

B. Substitutions will be permitted only when a Product becomes unavailable through no fault of the Contractor.

C. Document each request with complete data substantiating compliance of proposed Substitution with Contract.

D. A request for substitution constitutes a representation that the Contractor:

1. Has investigated proposed Product and determined that it meets or exceeds the quality level of the specified Product.

2. Will provide the same warranty for the Substitution as for the specified Product.

3. Will coordinate installation and make changes to other Work which may be required for the Work to be complete with no additional cost to Owner.

4. Waives claims for additional costs or time extension which may subsequently become apparent.

5. Will reimburse Owner for review or redesign services associated with re-approval by authorities.

E. Substitutions will not be considered when they are indicated or implied on shop drawing or product data submittals, without separate written request, or when acceptance will require revision to the Contract.

1.9 ALTERNATES

A. Alternates, which are other than specified, quoted on Bid will be reviewed and accepted or rejected as equivalents in accordance with the applicable General Requirements and applicable subsection 1.8 Substitutions of this Section.

B. If the quoted alternates are rejected after review by the Engineer, the Contractor shall provide substitutions in accordance with the Specifications and waive any claims for additional costs or time extension.


WATER PLANTS


01600-6

PART 2 - PRODUCTS

Not Used.

PART 3 - EXECUTIVE

Not used.

END OF SECTION


WATER PLANTS

STARTING OF SYSTEMS

01655-1

SECTION 01655 STARTING OF SYSTEMS

PART 1 - GENERAL

1.1 WORK INCLUDED

A. The Contractor shall initially start-up and place all equipment installed into successful operation according to manufacturer's written instructions and as directed by the manufacturer's field representative. Contractor shall provide all material, labor, tools, equipment, and expendables required. The start-up period shall be for a minimum of 14 calendar days with 24 hours of continuous operation each day.

B. General Activities include:

1. Cleaning.

2. Removing temporary protective coatings.

3. Flushing and replacing greases and lubricants, where required by manufacturer.

4. Lubrication.

5. Checking shaft and coupling alignments and reset where needed.

6. Checking and setting equipment rotation, safety interlocks, and belt tensions.

7. Checking and correcting, if necessary, leveling plates, grout, bearing plates, anchor bolts, fasteners, and alignment of piping which may put stress on pumping equipment connected to it.

8. Checking electrical and control compatibility.

9. Completing all required adjustments.

10. Providing product data.

C. Provide initial filling of lubricants and all other required operating fluids to proper levels.

D. Also provide fuel, electricity, water, filters, chemicals, and other expendables required for initial start-up of equipment and operation demonstration, unless otherwise specified.

1.2 MINIMUM START-UP PROCEDURES

A. Valves.

1. Inspect hand and automatic control valves, clean bonnets and stems.

2. Tighten packing glands to assure no leakage, but permit valve stems to operate without galling.

3. Replace packing in valves to retain maximum adjustment after system is judged complete.

4. Replace packing on any valve which continues to leak.

5. Remove and repair bonnets which leak.


WATER PLANTS

STARTING OF SYSTEMS

01655-2

6. Coat packing gland threads and valve stems with a surface preparation of "Moly-Cote" or "Mallow-Pro", after cleaning.

B. Verify that control valve seats are free from foreign material, and are properly positioned for intended use.

C. Tighten all pipe joints after system has been placed in operation. Replace gaskets which show any sign of leakage after tightening.

D. Inspect all joints for leakage.

1. Promptly remake each joint which appears to be faulty, do not wait for rust to form.

2. Clean threads on both parts, apply compound and remake joints.

E. After system has been placed in operation, clean strainers, dirt pockets, orifices, valve seats and headers in fluid system, to assure freedom from foreign materials.

F. Open traps and air vents where used, remove operating elements. Clean thoroughly, replace internal parts, and put back into operation.

G. Remove rust, scale and foreign material from equipment and renew defaced surfaces.

H. Set and calibrate equipment, including all electrical and control systems.

I. Inspect fan wheels for clearance and balance. Provide factory-authorized personnel for adjustment when needed.

J. Check each electrical control and power circuit to assure that operation complies with specifications and requirements to provide desired performance.

K. Inspect each pressure gage and thermometer for calibration. Replace items which are defaced, broken or which read incorrectly.

L. Repair damaged insulation.

M. Vent gasses trapped in any part of systems. Verify that liquids are drained from all parts of gas or air systems.

N. System components, valves, expansion joints shall be started by factory authorized personnel.

1.3 INITIAL FACILITY START-UP

A. Prior to start-up of the facilities, the Contractor will have prepared and pre-tested all equipment insofar as possible to check its ability for sustained operation, including inspections and adjustments by manufacturer's servicemen.

B. After the facilities are sufficiently complete to permit start-up, the Contractor, with the assistance of the Operator, will start-up the facilities as required. This assistance shall include the aid of any manufacturer’s representative requested by the Owner. The Contractor will be responsible for start-up of all facilities constructed under this Contract. During the initial start-up period for equipment and controls, the Contractor will check and provide for satisfactory mechanical operation of the facilities. The manufacturer's representatives shall be present during this period to instruct the plant operators in the care, operation, and maintenance of the equipment.


WATER PLANTS

STARTING OF SYSTEMS

01655-3

C. Prior to start-up of any equipment, the Contractor will prepare a schedule detailing the proposed start-up and his plans for manpower and auxiliary facilities to be provided. This start-up schedule and plan is subject to review by the Engineer.

D. Start-up of the facilities by the Contractor will include all mechanical facilities such as pumps, compressors, and like equipment, ventilating, air conditioning, or heating, plumbing and electrical systems.

E. The permanent plant power service is required for testing and initial start-up.

F. At the end of the start-up period, the Contractor will request written acceptance of start-up from the Owner if all equipment is operating within specified limits. If any or all of the facilities are not operating satisfactorily at the end of the start-up period, the Contractor will continue to operate those facilities, with the assistance of the Operator, that are incomplete or not operating satisfactorily until they are complete and acceptable to the Owner.

1.4 OPERATION DEMONSTRATION

A. When the start-up period is completed and accepted, the Contractor will demonstrate the ability of the plant to meet permit requirements by operating the plant with the assistance of the Operator for 14 consecutive calendar days (with 24 hours of continuous operation during each day) within a period of 30 days. All process units and equipment shall be operational during the 14-days of continuous 24 hour operation as described in start-up phasing below. If major equipment is not operational, Contractor will make necessary repairs and the 14-days of 24 hours of continuous operation shall start again. During this demonstration period, the Owner will provide all fuel, electricity and chemicals required to operate the entire plant. During this period, the Contractor will provide labor, spare parts, repairs and consumables required to operate the plant. Equipment warranties shall begin after successful completion of the 14-day period of 24 hours of continuous operation and upon approval of substantial completion by Owner’s representative.

B. At the successful completion of the demonstration period, the Owner will assume responsibility for operation of the facilities, provided the system is operating satisfactorily. Successful completion of the demonstration period will also be substantial completion for that portion of the facility.

1.5 MANUFACTURER’S REPRESENTATIVE

The manufacturers shall have a qualified representative present for initial equipment start and available during the initial start-up period and the operation demonstration period.

PART 2 - PRODUCTS

Not used.

PART 3 - EXECUTION

Not used.

END OF SECTION


WATER PLANTS

STARTING OF SYSTEMS

01655-4

BLANK PAGE


WATER PLANTS

INSTRUCTION OF OPERATION AND MAINTENANCE PERSONNEL

01661-1

SECTION 01661 INSTRUCTION OF OPERATION AND

MAINTENANCE PERSONNEL

PART 1 - GENERAL

1.1 REQUIREMENTS

A. The manufacturer shall provide the services of a factory trained maintenance specialist to instruct the Owner's operations and maintenance personnel in the recommended corrective and preventive maintenance procedures for equipment as specified in the respective equipment section.

B. The qualifications of the specialist shall be subject to approval by the Owner's Representative.

C. Manufacturer shall be responsible for coordinating these services at times acceptable to the Owner, with a minimum of 30 days prior notice.

D. Manufacturer shall provide a combination of classroom and field/machine shop training. All training shall be conducted at the project site.

1.2 SUBMITTALS

A. Manufacturer shall submit for approval a proposed Lesson Plan for the instruction, 30 days prior to commencement of scheduled training in accordance with Section 01330, Submittal Procedures.

B. Manufacturer shall submit for approval credentials of their designated maintenance instructor. Credentials will include a brief resume and specific details of the instructor's experience with maintenance of and training on the equipment specified.

1.3 INSTRUCTION LESSON PLAN

A. Manufacturer's proposed Lesson Plan shall include the elements presented in the Outline of Instruction Lesson Plan provided below. Specific components and procedures shall be identified in the proposed Lesson Plan.

B. Manufacturer's proposed Lesson Plan shall detail specific instruction topics. Training aids to be utilized in the instructions shall be referenced and attached where applicable to the proposed Lesson Plan. "Hands-on" demonstrations planned for the instruction shall be described in the Lesson Plan.

C. The manufacturer shall indicate the estimated duration of each segment of the training Lesson Plan.

D. Outline of Instruction Lesson Plan.

1. Equipment Operation.

a. Describe equipment's operating (process) function.

b. Describe equipment's fundamental operating principals and dynamics.


WATER PLANTS


01661-2

c. Identify equipment's mechanical, electrical and electronic components and features.

d. Identify all support equipment associated with the operation of subject equipment (i.e., air intake filters, valve actuators, motors).

2. Detailed Component Descriptions.

a. Identify and describe in detail each component's function.

b. Where applicable, group related components into subsystems. Describe subsystem functions and their interaction with other subsystems.

c. Identify and describe in detail equipment safeties and control interlocks.

3. Equipment Preventive Maintenance (PM).

a. Describe PM inspection procedures to:

1) Perform an inspection of the equipment in operation.

2) Spot potential trouble symptoms (anticipate breakdowns).

3) Forecast maintenance requirements (predictive maintenance).

b. Define the recommended PM intervals for each component.

c. Provide lubricant and replacement part recommendations and limitations, along with recommended spare parts.

d. Describe appropriate cleaning practices and recommended intervals.

4. Equipment Troubleshooting.

a. Define recommended systematic troubleshooting procedures.

b. Provide component specific troubleshooting checklists.

c. Describe applicable equipment testing and diagnostic procedures to facilitate troubleshooting.

5. Equipment Corrective Maintenance.

a. Describe recommended equipment preparation requirements.

b. Identify and describe the use of any special tools required for maintenance of the equipment.

c. Describe component removal/installation and disassembly/assembly procedures.

d. Perform at least two "hands-on" demonstrations of common corrective maintenance repairs.

e. Describe recommended measuring instruments and procedures, and provide instruction on interpreting alignment measurements, as appropriate.

f. Define recommended torquing, mounting, calibration and/or alignment procedures and settings, as appropriate.


WATER PLANTS


01661-3

g. Describe recommended procedures to check/test equipment following a corrective repair.

1.4 TRAINING AIDS

A. The manufacturer's instructor shall incorporate training aids as appropriate to assist in the instruction. At a minimum, the training aids shall include text and figure handouts. Other appropriate training aids are:

1. Audiovisual aids such as films, slides, DVDs, overhead transparencies, posters, blueprints, diagrams, and catalogue sheets.

2. Equipment cutaways and samples such as spare parts, damaged equipment, etc.

3. Tools such as repair tools, customized tools, measuring and calibrating instruments.

B. The manufacturer's instructor shall utilize descriptive class handouts during the instruction. Photocopied class handouts shall be good quality reproductions. Class handouts should accompany the instruction with frequent reference made to them. Customized handouts developed especially for the instruction are encouraged. Handouts planned for the instruction shall be attached with the manufacturer's proposed Lesson Plan.

1.5 "HANDS-ON" DEMONSTRATIONS

A. The manufacturer's instructor shall present at least one "hands-on" demonstration of common corrective maintenance repairs so that all operation and maintenance personnel have the opportunity to witness the demonstration. The manufacturer shall provide the tools and equipment to conduct the demonstrations. Requests for supplemental assistance and facilities should be submitted with the manufacturer's proposed Lesson Plan. The proposed "hands-on" demonstrations should be described in the manufacturer's proposed Lesson Plan.

B. In any "hands-on" training situation where Owner's operation or maintenance personnel participate in disassembly or assembly of equipment components, the manufacturer shall be responsible for such disassembly or assembly and shall provide written certification of proper equipment operation to the Engineer.

PART 2 - PRODUCTS

Not used.

PART 3 - EXECUTION

Not used.

END OF SECTION


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01661-4

BLANK PAGE


WATER PLANTS

CUTTING AND PATCHING

01730-1

SECTION 01730


PART 1 - GENERAL

1.1 SUMMARY

Contractor shall be responsible for all cutting, fitting and patching, including attendant excavation and backfill, required to complete the work or to:

A. Make its multiple components fit together properly.

B. Uncover portions of the work to provide for installation of ill-timed work.

C. Remove and replace defective work.

D. Remove and replace work not conforming to the requirements of Contract Documents.

E. Remove samples of installed work as specified for testing.

F. Provide routine penetrations of nonstructural surfaces for installation of ductwork, piping and electrical conduit.


A. Section 01010 – Summary of Work.

B. Section 01330 – Submittal Procedures.

C. Section 15010 – Basic Mechanical Requirements.

D. Section 15011 – Basic Mechanical Procedures and Methods.

1.3 SUBMITTALS

A. Submit a written request to Owner’s Representative well in advance of executing any cutting or alteration which affects:

1. The work of the Owner or any separate Contractor.

2. The structural value or integrity of any element of the project.

3. The integrity or effectiveness of weather-exposed or moisture-resistant elements or systems.

4. The efficiency, operational life, maintenance or safety of operational elements.

5. The visual qualities of sight-exposed elements.

B. The request shall include:

1. Identification of the project.

2. The reason for cutting, alteration or excavation.

3. The effect of the work on the Owner or any separate Contractor, or on the structural or weatherproof integrity of the project.

4. Written permission of any separate Contractor whose work will be affected.


WATER PLANTS


01730-2

5. Description of the proposed work.

a. The scope of cutting, patching, alteration or excavation.

b. The trades who will execute the work.

c. Products proposed to be used.

d. The extent of refinishing to be done.

6. Alternatives to cutting and patching.

7. Cost proposal, when applicable.

C. Should conditions of the work or the schedule indicate a change of products from the original installation, Contractor shall submit a request for substitution as specified in Section 01600 – Materials and Equipment.

D. Submit a written notice to Owner’s Representative designating the date and the time the work will be uncovered.

PART 2 - PRODUCTS

Comply with specifications and standards for each specific product involved.

PART 3 - EXECUTION

3.1 INSPECTION

A. Inspect existing conditions of the project, including elements subject to damage or to movement during cutting and patching.

B. After uncovering work, inspect the conditions affecting the installation of products or performance of the work.

C. Report unsatisfactory or questionable conditions in writing; do not proceed with the work until the Owner’s Representative has provided further instructions.

3.2 PREPARATION

A. Provide adequate temporary support as necessary to assure the structural value or integrity of the affected portion of the work.

B. Provide devices and methods to protect other portions of the project from damage.

C. Provide protection from the elements for that portion of the project which may be exposed by cutting and patching work, and maintain excavations free from water.

3.3 PERFORMANCE

A. Execute cutting and demolition by methods which will prevent damage to other work, and will provide proper surfaces to receive installation or repairs.

B. Execute excavating and backfilling by methods which will prevent settlement or damage to other work.

C. Employ the original installer or fabricator to perform cutting and patching for:


WATER PLANTS


01730-3

1. Weather-exposed or moisture-resistant elements.

2. Sight-exposed finished surfaces.

D. Execute fitting and adjustment of products to provide a finished installation to comply with specified products, functions, tolerances and finishes.

E. Restore work which has been cut or removed; install new products to provide completed work in accordance with the requirements of the Contract Documents.

F. Fit work airtight to pipes, sleeves, ducts, conduit and other penetrations through surfaces.

END OF SECTION


WATER PLANTS


01730-4

BLANK PAGE


WATER PLANTS

CLEANING AND ADJUSTING

01740-1

SECTION 01740


PART 1 - GENERAL

1.1 SUMMARY

A. The Contractor is responsible for cleaning and adjusting the work. If the Contractor fails to clean and adjust the work in accordance with the requirements of this Section, the Owner may do so and charge the resulting costs to the Contractor.

B. Contractor is responsible for conducting the specific cleaning and adjusting requirements as described in the individual sections of the technical specifications.

1.2 REQUIREMENTS OF REGULATORY AGENCIES

A. Fire Protection. Store volatile waste in covered metal containers and remove from premises daily.

B. Pollution Control. Conduct cleaning and disposal operations in compliance with local ordinances and antipollution laws.

1. Burning or burying of rubbish and materials on the project site is not permitted.

2. Disposal of volatile fluid wastes and other chemical wastes in storm or sanitary sewer systems or into streams or waterways is not permitted.

C. Safety Standards. Maintain the project in accordance with insurance and safety standards.

PART 2 - PRODUCTS

2.1 MATERIALS

Use only cleaning materials approved by the manufacturer on surfaces designated for cleaning. Employ cleaning materials in the manner recommended by the cleaning material manufacturer.

PART 3 - EXECUTION

3.1 DURING CONSTRUCTION

A. Oversee cleaning and ensure that the premises are maintained free from accumulations of waste material and rubbish. Do not allow waste materials, rubbish and debris to accumulate and become unsightly or create a hazard. Provide on-site containers for collection of waste material, rubbish and debris.

B. At least twice per month during the progress of the work, collect and dispose of waste material, rubbish and debris. Handle waste in a controlled manner; do not drop or throw materials from heights.

C. Remove waste materials, rubbish and debris from the site and legally dispose at public or private dumping areas off the project site.


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01740-2

3.2 FINAL CLEANING AND ADJUSTING

A. Use experienced workmen or professional cleaners to conduct final cleaning of the project site.

B. Remove grease, dust, dirt, stains, paint, oil, labels, fingerprints and other foreign materials from interior and exterior surfaces. Repair, patch and touch-up marred surfaces to match adjacent finishes.

C. Broom clean paved surfaces; rake clean other surfaces of grounds.

D. If installed features of the work fail to operate or operate improperly, make the necessary adjustments to prevent damage and ensure proper operation. Remove and repair or replace maladjusted items if necessary for proper adjustment.

E. Remove all waste material and rubbish from the project area, as well as all tools, construction equipment, machinery, surplus materials and temporary facilities.

F. Immediately prior to acceptance or occupancy, conduct a final inspection of exposed interior and exterior surfaces to verify that the work is properly cleaned. Maintain cleaning until the premises are occupied by the Owner.

3.3 ADJACENT AREAS

To the Owner's satisfaction, clean or repair adjacent areas affected by construction activities. Remove dust and debris from the adjacent area. Repair, patch and touch-up marred surfaces to match adjacent finishes.

END OF SECTION


WATER PLANTS

WASTE MATERIAL DISPOSAL

01750-1

SECTION 01750


PART 1 - GENERAL

1.1 MEASUREMENT AND PAYMENT

A. No separate measurement and payment will be made. Include cost of work in contract bid prices.

PART 2 - PRODUCTS

2.1 EQUIPMENT AND MATERIALS

A. Specific products are not required. Use equipment and materials necessary to properly complete disposal of waste materials.

B. Obtain approval for equipment and materials before beginning disposal of waste materials

PART 3 - EXECUTION

3.1 DISPOSAL AREA

A. All waste material becomes property of the Contractor and must be removed from the work site and disposed of in a legal manner not to damage the Owner or other persons. Provide copies of all disposal manifests to the Owner.

B. The Owner will designate controlled spoil areas within 1 mile free haul distance within the limits of his property for disposal of waste materials.

C. Strip the disposal area of vegetation, humus or other debris. Strippings become property of Contractor to be legally disposed of with other waste materials.

D. Protect trees designated for preservation. Take special care not to damage trees designated for preservation which are outside limits of waste disposal areas.

3.2 BURNING

A. Burning of waste materials will not be permitted on Owner’s controlled property.

3.3 COMPACTION AND GRADING

A. Compact waste materials to the density of the surrounding area. Shape the area for proper drainage. Place excess topsoil on waste material in an even layer not greater than 3 inches thick and grade smooth.

END OF SECTION


WATER PLANTS


01750-2

BLANK PAGE


WATER PLANTS

CLOSEOUT PROCEDURES

01770-1

SECTION 01770

CLOSEOUT PROCEDURES

PART 1 - GENERAL

1.1 SUMMARY

This Section includes the requirements for the Contractor’s closeout procedures.


A. Division 0 – Front End Documents.

B. Section 01740 – Cleaning and Adjusting.

C. Section 01781 – Project Record Documents.

1.3 SUBSTANTIAL COMPLETION AND INSPECTION

A. The Contractor shall submit the following items prior to requesting substantial completion:

1. Operation and Maintenance Data, and evidence of Instructions to Owner's Personnel. Submit in accordance with Section 01661 – Instruction of Operation and Maintenance Personnel, and Section 01800 – Operations and Maintenance Data.

2. Spare Parts and Maintenance Materials. Submit in accordance with Section 01790 – Spare Parts and Maintenance Materials, and as specified in the respective sections of the technical specifications.

B. When Contractor considers the work substantially complete, Contractor shall submit:

1. A written notice that the work, or designated portion thereof, is substantially complete and that the project start-up has been satisfactorily completed and approved by Owner.

2. A list of items to be completed or corrected.

C. Within a reasonable time after receipt of such notice, the Owner’s Representative will make an inspection to determine the status of completion.

D. Should the Owner’s Representative determine that the work is not substantially complete, he will promptly notify the Contractor in writing, giving the reasons therefore.

1. Contractor shall remedy the deficiencies in the work, and submit a second written notice of substantial completion.

2. Owner’s Representative will re-inspect the work.

E. When Owner’s Representative finds that the work is substantially complete, he will:

1. Prepare and deliver to Owner a tentative Certificate of Substantial Completion with a tentative list of items to be completed or corrected before final payment.


WATER PLANTS

CLOSEOUT PROCEDURES

01770-2

2. After due consideration of any objections to the tentative certificate that have been made by the Owner, the Owner’s Representative will execute and deliver to the Owner and Contractor a final Certificate of Substantial Completion with a revised list of items to be completed or corrected.

1.4 FINAL INSPECTION

A. When Contractor considers the work complete, he shall submit written certification that:

1. Contract Documents have been reviewed.

2. Work has been inspected for compliance with Contract Documents.

3. Work has been completed in accordance with the Contract Documents.

4. Equipment and systems have been tested in the presence of the Owner's representative and are operational.

5. Work is completed and ready for final inspection.

B. Owner’s Representative will make an inspection to verify the status of completion with reasonable promptness after receipt of such certification.

C. Should the Owner’s Representative consider the work is incomplete or defective:

1. Owner’s Representative will promptly notify the Contractor in writing, listing the incomplete or defective work.

2. Contractor shall take immediate steps to remedy the stated deficiencies, and submit a second written certification that the work is complete.

3. Owner’s Representative will re-inspect the work.

D. When the Owner’s Representative finds the work is acceptable under the Contract Documents, he shall request the Contractor to make closeout submittals.

1.5 CONTRACTOR'S CLOSEOUT SUBMITTALS

A. Project Record Documents. As described in Section 01781.

B. Operations and Maintenance Data. As described in Section 01800.

C. Instructions to Operation and Maintenance Personnel. As described in Section 01661.

D. Spare Parts and Maintenance Materials. As described in Section 01790 and in the respective sections of the technical specifications.

E. Evidence of Payment and Release of Liens. Submit the following in such form as approved by Owner.

1. Contractor's affidavit of payment of debts and claims.

2. Contractor's affidavit of release of liens, with:

a. Consent of surety to final payment.

b. Separate releases or waivers of liens for subcontractors and others with lien rights against property of Owner with a list of those parties.


WATER PLANTS

CLOSEOUT PROCEDURES

01770-3

1.6 FINAL ADJUSTMENT OF ACCOUNTS

A. Submit a final statement of accounting which shall reflect all adjustments to the contract sum thus:

1. Original contract sum.

2. Additions and deductions resulting from:

a. Previous change orders.

b. Allowances.

c. Unit prices.

d. Deductions for uncorrected work.

e. Deductions for liquidated damages.

f. Other adjustments.

3. Total contract sum, as adjusted.

4. Previous payments.

5. Sum remaining due.

B. Owner’s Representative will prepare final change order, reflecting approved adjustments to contract sum which were not previously made by change orders.

1.7 FINAL APPLICATION FOR PAYMENT

Contractor shall submit the final application for payment in accordance with procedures and requirements stated in Contract Documents.

PART 2 - PRODUCTS

Not used.

PART 3 - EXECUTION

Not used.

END OF SECTION


WATER PLANTS

CLOSEOUT PROCEDURES

01770-4

BLANK PAGE


WATER PLANTS

PROJECT RECORD DOCUMENTS

01781-1

SECTION 01781


PART 1 - GENERAL

1.1 SUMMARY

This Section includes the requirements for the preparation and maintenance of record documents for the project to reflect accurately the construction as built. Documents shall be submitted following the completion of the work, as a condition of final acceptance.

1.2 MAINTENANCE OF RECORD DOCUMENTS

A. Maintain at the job site, one copy of the following as Project Record Documents:

1. Contract drawings.

2. Project Manual.

3. Addenda.

4. Reviewed shop drawings.

5. Approved samples.

6. Change orders and field orders.

7. Field test records.

8. Correspondence.

B. Store record documents in an approved location apart from documents used for construction. Do not use record documents for construction purposes. Provide files and racks for orderly storage. Maintain documents in clean, dry, legible condition. Make documents and samples available at all times for inspection by the Owner's Representative.

1.3 MARKING DEVICES

Mark all changes legibly in a contrasting color.

1.4 RECORDING

A. Keep record documents current. Do not permanently conceal any work until required information has been recorded.

B. Label each document "PROJECT RECORD" in neat, large, printed letters. Legibly mark contract drawings to record actual construction, showing:

1. Depths of various elements of foundation in relation to grade.

2. Horizontal and vertical location of underground and underslab utilities and appurtenances referenced to permanent surface improvements.

3. Location of internal utilities and appurtenances referenced to permanent surface improvements.

4. Field changes of dimension and detail.


WATER PLANTS


01781-2

5. Changes made by change order or field order.

6. Details not on original contract drawings.

C. Legibly mark specifications and addenda to record:

1. Manufacturer, trade name, catalog number and supplier of each product and item of equipment actually installed.

2. Changes made by change order or field order.

3. Other matters not originally specified.

D. Legibly annotate shop drawings to record changes made after review.

E. Delete Engineer's seals from record documents.

1.5 SUBMITTAL

A. At project completion, submit record documents as required in Section 01781. Place all letter sized material in a 3-ring binder, neatly indexed. Bind contract drawings and shop drawings in rolls of convenient size for ease of handling.

B. Accompany the submittal with a transmittal letter in duplicate, containing:

1. Date.


3. Contractor's name and address.

4. Title and number of each record document.

5. Certification that each document as submitted is complete and accurate.

6. Signature of Contractor.

PART 2 - PRODUCTS

Not used.

PART 3 - EXECUTION

Not used.

END OF SECTION


WATER PLANTS

WARRANTIES AND BONDS

01785-1

SECTION 01785


PART 1 - GENERAL

1.1 SUMMARY

This Section includes the requirements for the warranties and bonds to be issued by the Contractor as part of the work under the Contract.


A. Division 0 – Front End Documents.

B. Section 01770 - Closeout Procedures.

1.3 SUBMITTALS

A. Requirements.

1. Assemble two (2) original signed copies of all warranties, bonds, and service and maintenance contracts, executed by each of the respective manufacturers, suppliers and subcontractors.

2. Provide complete information for each item, including, but not limited to, the following information:

a. Product or work item.

b. Firm, with name of principal, address and telephone number.

c. Scope.

d. Date of beginning and duration of warranty, bond, or service and maintenance contract.

e. Proper procedure for Owner's personnel in case of failure.

f. Instances which might affect validity of warranty or bond.

3. Provide a table of contents, neatly typed, in orderly sequence.

4. Place a copy of the equipment warranties in the Operations and Maintenance Manual for the equipment.

5. Submit a spreadsheet with complete information for each item of installed equipment, including, but not limited to:

a. Complete list of all equipment installed.

b. Equipment installation dates.

c. Equipment acceptance dates.

d. Scheduled equipment check dates.

e. A sign-off location for each item for acceptance by Owner.


WATER PLANTS


01785-2

B. Form.

1. Prepare submittals in duplicate packets bound in 3-ring binders of commercial quality with cleanable plastic covers.

2. All materials should be 8-1/2″ x 11″ (larger sheets shall be folded to fit binders), punched to fit the 3-ring binders.

3. Include a cover sheet identifying each packet with the title: "WARRANTIES AND BONDS." Also list the project title and name of Contractor.

C. Warranty.

1. Warranties shall start on the date of substantial completion. Make submittals within 10 days after date of substantial completion, and prior to final request for payment.

2. For equipment or component parts of equipment put into normal service during progress of construction, submit documents within 10 days after inspection and acceptance, listing the date of acceptance as the start of the warranty period.

3. For items of work where acceptance is delayed materially beyond the date of substantial completion, provide updated submittal within 10 days after acceptance, listing the date of acceptance as the start of the warranty period.

4. Warranty period for equipment shall, in general, be for one year, Individual equipment specifications will have precedence if the stated warranty period of the specification is for other than one year.

PART 2 - PRODUCTS

Not used.

PART 3 - EXECUTION

Not used.

END OF SECTION


WATER PLANTS

SPARE PARTS AND MAINTENANCE MATERIALS

01790-1

SECTION 01790


PART 1 - GENERAL

1.1 SUMMARY

A. Contractor shall furnish spare parts and maintenance materials as specified in the individual sections of the specifications.

B. Parts and materials shall be furnished in manufacturer's unopened cartons, boxes, crates or other protective covering suitable for preventing corrosion or deterioration for the maximum length of storage which may be normally anticipated. They shall be clearly marked and identified.

C. During construction, store all parts and maintenance materials in buildings or trailers with floor, roof and closed sides and in accordance with manufacturer's recommendations. Protect from weather, condensation and humidity.

D. Parts and materials shall be delivered to the Owner upon completion of the work or when the Owner assumes beneficial occupancy. Contractor shall then place them in permanent storage rooms or areas approved by the Owner.

E. Provide a letter of transmittal including the following:

1. Date of letter and transfer of parts and materials.

2. Contract title and number.

3. Contractor's name and address.

4. A complete inventory of the parts and material, listing the applicable specification section for each.

5. A place for the Owner to sign and signify receipt of the parts and materials.

F. Contractor shall be fully responsible for loss or damage to parts and materials until they are transmitted to the Owner.

PART 2 - PRODUCTS

Not used.

PART 3 - EXECUTION

Not used.

END OF SECTION


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01790-2

BLANK PAGE


WATER PLANTS

POST FINAL INSPECTION

01795-1

SECTION 01795


PART 1 - GENERAL

1.1 SUMMARY

A. Approximately one year after the Letter of Conditional Approval has been received by the Contractor, the Owner’s Representative will make arrangements with the Owner and the Contractor for a post final inspection and will send a written notification to said parties to inform them of the date and time of the inspection.

B. After the inspection, the Owner’s Representative will inform the Contractor of any corrections required.

C. When the corrections have been satisfactorily completed, the Owner’s Representative will forward a certificate for the release of bonds.

PART 2 - PRODUCTS

Not used.

PART 3 - EXECUTION

Not used.

END OF SECTION


WATER PLANTS


01795-2

BLANK PAGE


WATER PLANTS

OPERATIONS AND MAINTENANCE DATA

01800-1

SECTION 01800


PART 1 - GENERAL

1.1 SUMMARY

This Section includes the submittal requirements for equipment and facility operating and maintenance manuals.


A. Section 01330 – Submittal Procedures.

B. Section 01600 – Materials and Equipment.

C. Section 01770 – Closeout Procedures.

D. Manufacturer's Operations and Maintenance Data. Individual Specifications Sections.

1.3 SUBMITTALS

A. In addition to the project submittals required by Section 01330, Submittal Procedures, submit a list of operation and maintenance manuals and parts manuals to be provided.

B. Submit documents, bound in 8-1/2” x 11” text pages, 3-ring/D binders with durable plastic covers.

C. Prepare binder covers with printed title "OPERATION AND MAINTENANCE INSTRUCTIONS", title of project, and subject matter of binder when multiple binders are required.

D. Internally subdivide the binder contents with permanent page dividers, logically organized as described below; with tab titling clearly printed under reinforced laminated plastic tabs.

E. Contents. Prepare a Table of Contents for each volume, with each product or system description identified.

1. Part 1. Directory, listing names, addresses, and telephone numbers of Architect/Engineer, Contractor, Subcontractors, and major equipment suppliers.

2. Part 2. Operation and maintenance instructions, arranged by system. For each category, identify names, addresses, and telephone numbers of Subcontractors and suppliers. Identify the following:

a. Significant design criteria.

b. List of equipment.

c. Parts list for each component.

d. Operating instructions.

e. Maintenance instructions for equipment and systems.

f. Maintenance instructions for special finishes, including recommended cleaning methods and materials and special precautions identifying detrimental agents.


WATER PLANTS


01800-2

3. Part 3. Project documents and certificates, including the following:

a. Shop drawings and product data.

b. Water balance (pressure settings) reports.

c. Certificates.

d. Photocopies of warranties.

F. At least one month prior to placing the equipment or facility in service, submit two (2) copies of operation and maintenance manual and parts manual for review.

G. Submit completed volumes in final form 10 days prior to completion of the work.

1.4 EQUIPMENT OPERATION AND MAINTENANCE DATA

A. Furnish operation and maintenance manuals for all equipment. Operation and maintenance manual must contain all information required for Owner to operate, maintain, and repair equipment. The manual must be prepared by equipment manufacturer, furnished to the Engineer by Contractor, and, as a minimum, contain the following:

1. Equipment functions, normal operating characteristics, and limiting conditions.

2. Assembly, installation, alignment, adjustment, and checking instructions.

3. Operating instructions for start-up, normal operation, regulation and control, normal shutdown, and emergency shutdown.

4. Lubrication and detailed maintenance instructions. The maintenance instructions are to include detailed drawings giving the location of each maintainable part and lubrication point and detailed instructions on disassembly and reassembly of the equipment.

5. Troubleshooting guide.

6. Complete spare parts list with predicted life of parts subject to wear, lists of spare parts recommended on hand for both initial start-up and for normal operating inventory, and local or nearest source of spare parts availability.

7. Outline, cross-section, and assembly drawings; engineering data; wiring diagram.

8. Test data and performance curves.

B. Furnish parts manuals for all equipment. The manual must be prepared by equipment manufacturers, furnished to Engineer by Contractor, and, as a minimum, contain the following:

1. Detailed drawings giving the location of each maintainable part.

2. Complete spare parts list with predicted life of parts subject to wear, lists of spare parts recommended on hand for both initial start-up and for normal operating inventory, and local or nearest source of spare parts availability.


WATER PLANTS


01800-3

PART 2 - PRODUCTS

Not used.

PART 3 - EXECUTION

Not used.

END OF SECTION


WATER PLANTS


01800-4

BLANK PAGE


WATER PLANTS

DEMOLITION

02060-1

SECTION 02060

DEMOLITION

PART 1 - GENERAL


A. Demolition and removal from site of designated structures including all equipment, piping, fixtures, utilities, and miscellaneous items.

B. Demolition and removal of foundations, as noted on the drawings.

C. Disconnection filling and capping of utilities.

D. Filling of voids created by demolition.


A. Section 01325 – Construction Schedules.

B. Section 01500 - Construction Facilities and Temporary Controls.

C. Section 01600 - Materials and Equipment.

D. Section 01770 - Closeout Procedures.

1.3 SUBMITTALS

A. Submit under provisions of Section 01330.

B. Shop Drawings: Indicate demolition and removal sequence and location of salvageable items; location and construction of fences.

C. Dust and Fume Collection System: Indicate barriers and containment systems to be used under Provisions of Section 01500.

1.4 PROJECT RECORD DOCUMENTS


B. Accurately record actual locations of capped utilities and subsurface obstructions.

1.5 REGULATORY REQUIREMENTS

A. Conform to applicable code for demolition of structures, safety of adjacent structures, dust control, runoff control, disposal, and protection of adjacent trees and shrubbery.

B. Obtain required permits from authorities.

C. Notify affected utility companies before starting work and comply with their requirements.

D. Do not close or obstruct roadways, sidewalks, or hydrants without permission.

E. Conform to applicable regulatory procedures when hazardous or contaminated materials are discovered.

1.6 SCHEDULING

A. Schedule work under the provisions of Section 01325.

B. Describe demolition removal procedures and schedule.


WATER PLANTS

DEMOLITION

02060-2

PART 2 - PRODUCTS

2.1 FILL MATERIALS

A. Fill Material (Earthen): Refer to Sections 02223, 02923, and 02936.

B. Pipe Fill Material: Fill interior of existing 42” header with CLSM (Controlled Low Strength Material) flowable fill as indicated on drawings and as specified in Section 02293.

PART 3 - EXECUTION

3.1 PREPARATION

A. Provide, erect, and maintain temporary barriers and partitions for safety and dust control.

B. Protect existing landscaping materials, appurtenances and structures and utilities which are not to be demolished.

C. Mark location of utilities.

3.2 DEMOLITION REQUIREMENTS

A. Conduct demolition operations with minimum interference to access to site by Owner personnel. Maintain egress and access at all times.

B. Sprinkle Work with water to minimize dust. Provide hoses and water connections for this purpose.

C. All materials and equipment removed from existing work shall become the property of the Contractor, except for those which the Owner has identified and marked to remain the property of Owner. All materials and equipment marked to remain the property of Owner shall be carefully removed so as not to be damaged, and then cleaned and stored on or adjacent to the site in a protected place until delivery to the Owner has been scheduled. Contractor shall coordinate delivery of salvaged equipment and materials with:

Jason Miller Water & Sewer Maintenance Superintendent City of Conroe 401 Sgt. Ed Holcomb Blvd South Conroe, Tx. 77304 Phone: (936) 522-3870

D. Contractor shall dispose of all demolition materials, equipment, debris, and all other items not marked by the Engineer to remain the property of Owner, off the site and in conformance with all existing applicable laws and regulations.

3.3 DEMOLITION

A. For specific items to be removed and discarded refer to the Contract Documents.

END OF SECTION


WATER PLANTS

VALVE BOXES, METER BOXES, AND METER VAULTS 02085-1

SECTION 02085

VALVE BOXES, METER BOXES, AND METER VAULTS

PART 1 - GENERAL


A. Valve boxes for water service.

B. Meter boxes for water service.

C. Meter vaults for water service.

1.2 REFERENCES

A. ASTM A 48 - Standard Specification for Gray Iron Castings.

B. ASTM D 256 - Standard Test Methods for Determining the Izod Pendulum Impact Resistance of Plastics.

C. ASTM D 638 - Standard Test Method for Tensile Properties of Plastics.

D. ASTM D 648 - Standard Test Method for Deflection Temperature of Plastics Under Flexural Load in the Edgewise Position.

E. ASTM D 790 - Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials.

F. ASTM D 2240 - Standard Test Method for Rubber Property-Durometer Hardness.

1.3 SUBMITTALS

A. Conform to requirements of Section 01330 - Submittal Procedures.

B. Submit manufacturers’ product data for following items for approval:

1. Each type of valve box and lid.

2. Each type of meter box and cover.

3. Each type of meter vault frame and cover.

C. Submit design calculations and shop drawings for precast vault elements, sealed by an Engineer registered in State of Texas.

D. Submit shop drawings for cast-in-place meter vaults for approval if proposed construction varies from City of Conroe Detail Drawings.

E. Submit manufacturer's certification that plastic meter boxes meet requirements of Paragraph 2.05, Plastic Meter Boxes.


WATER PLANTS


PART 2 - PRODUCTS

2.1 VALVE BOXES

A. Provide approved Type A, cast-iron/ductile-iron, slide-type, valve boxes. Design of valve box shall minimize stresses on valve imposed by loads on box lid.

B. Cast letter “W” into lid, 1/2 inch in height and raised 3/32 inch, for valves serving potable water lines.

C. Unless otherwise specified, uncoated cast iron.

D. Riser Pipe.

1. Provide 6-inch PVC, DR 18, riser pipes

or

2. 6-inch ductile-iron, thickness Class 51 riser pipes in accordance with Section 15106 – Ductile Iron Pipe and Fittings.

3. Provide single section of pipe.

E. Concrete for valve box placement:

1. For locations in new concrete pavement, provide strength and mix design of new pavement.

2. For other locations, provide concrete for sidewalks conforming to requirements of Section 02751 - Concrete Paving.

2.2 METER BOXES

A. Provide meter boxes for 5/8-inch through 1-inch meters of the following materials:

1. Non-traffic bearing locations: Cast iron, concrete or plastic.

2. Traffic bearing locations: Cast iron.

B. Provide meter boxes for 1 1/2-inch and 2-inch meters of cast iron.

C. Provide meter box with reading lid. Provide lids with spring-type latching devices. Lids shall contain sufficient metal that meter box can be easily located with metal detector. Cast words “CITY OF CONROE” and "WATER METER" into lid with letters of 1/2-inch height and raised 3/32 inch.

D. Meter box dimensions shall conform to the following approximate dimensions:

1. Length: At top – 15 1/2 inches; at bottom 20 inches

2. Width: At top – 12 1/2 inches; at bottom 14 3/4 inches

3. Height: 12 inches

E. Extensions: Meter box extensions 3 inches and 6 inches in height shall be available from manufacturer as standard item.


WATER PLANTS


2.3 CAST-IRON METER BOXES

A. Cast-Iron Boxes: Clean and free from sand blow-holes or other defects conforming to requirements of ASTM A 48, Class 30B. Bearing surfaces shall be machined so that covers seat evenly in frames.

B. Boxes and lids shall have dipped, coal-tar-pitch, varnish finish.

C. Provide lock-type meter boxes when required by Drawings. Lock mechanisms shall work with ease.

2.4 CONCRETE METER BOXES

A. Concrete Meter Boxes: Conform to Section 03310 – Cast-in-Place Concrete. Construct to dimensions shown on Drawings.

B. Castings: Free from fractures, large or deep cracks, blisters or surface roughness or any other defects that may affect serviceability.

2.5 PLASTIC METER BOXES

A. Plastic Meter Boxes: Made of high density polyethylene conforming to the following ASTM standards:

ASTM REQUIREMENT

D 256 Impact Strength = 1.9 ft.-lb./inch (Izod, Notched)

D 256 Impact Strength = 6.4 ft.-lb./inch (Izod, Un-Notched)

D 638 Tensile Strength (2.0 min.) = 3400 psi

D 648 Deflection Temperature = 170 degrees F

D 2240 Shore D, Hardness, 55-65 Impact Strength, Falling Dart Method, 160 inch-lb.

D 790 Flexural Modulus = 90,000 psi

B. Meter boxes shall meet the following test requirements:

1. Static Load: Not less than 2500 pounds using 6-inch disc with direct compression exerted at center of top of meter box with solid plastic lid.

2. Deflection: Not less than 1000 pounds load required to deflect top edge of meter box 1/8- inch.

C. Meter box body, without lid, shall weigh approximately 7 pounds.


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2.6 METER VAULTS

A. Meter vaults may be constructed of precast concrete, cast-in-place concrete to the specified dimensions in the City of Conroe Detail Drawings.

B. Concrete for Meter Vaults: Conform to requirements of Section 03310 – Cast-in-Place Concrete.

C. Reinforcing steel for meter vaults: Conform to requirements of Section 03210 – Concrete Reinforcement.

D. Grates and Covers: Conform to requirements of Section 02607 – Precast Manholes and Covers.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Obtain approval from Owner’s Representative for location of meter vault.

B. Verify lines and grades are correct.

C. Verify compacted subgrade will support loads imposed by vaults.

3.2 VALVE BOXES

A. Install riser pipe with suitable length for depth of cover indicated on Drawings or to accommodate actual finish grade.

1. Install with bell on top of valve

2. Place riser pipe in plumb, vertical position

B. Install valve box and riser piping plumbed in a vertical position. Provide 6-inches telescoping freeboard space between riser pipe top butt end, and interior contact flange of valve box, for vertical movement damping. End of pipe resting on valve shall be notched out sufficiently to provide a snug fit around the valve bonnet and to center valve inside of pipe.

C. Set, align, and adjust valve box so that lid is level with final grade.

D. Paint covers of new valve boxes in fluorescent orange when installed. After completion and acceptance by City, repaint covers black.

3.3 METER BOXES

A. Install cast iron or plastic boxes in accordance with manufacturer’s instructions.

B. Construct concrete meter boxes to dimensions shown on City of Conroe Detail Drawings.

C. Adjust top of meter boxes to conform to cover elevations specified in Paragraph 3.05, Frame and Cover for Meter Vaults.

D. Do not locate under paved areas unless approved by Owner’s Representative. Use approved traffic type box with cast iron lid when meter must be located in paved areas.

3.4 METER VAULTS

A. Construct concrete meter vaults to dimensions shown on City of Conroe Detail Drawings.


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Do not cast in presence of water. Make bottom uniform. Verify lines and grades are correct and compacted subgrade will support loads imposed by vaults. Interior meter vault depth is not allowed to exceed more than 4 feet unless approved by OCE.

B. Precast Meter Vaults:

1. Install precast vaults in accordance with manufacturer’s recommendations. Set level on a minimum 3-inch-thick bed of sand conforming to requirements of Section 02315 – Excavation Trenching and Backfill for Utilities.

2. Seal lifting holes with cement-sand mortar or non-shrink grout.

C. Meter Vault Floor Slab:

1. Construct floor slabs of 6-inch-thick reinforced concrete. Slope floor 1/4 inch per foot toward sump. Make sump 12 inches in diameter, or 12 inches square, and 4 inches deep, unless other dimensions are required by Drawings. Install dowels at maximum of 18 inches, center-to-center for keying walls to floor slab.

2. Precast floor slab elements may be used for precast vault construction

D. Cast-in-Place Meter Vault Walls:

1. Key walls to floor slab and form to dimensions shown on Drawings. Minimum wall thickness shall be 4 inches.

2. Cast walls monolithically. One cold joint will be allowed when vault depth exceeds 12 feet.

3. Set frame for cover in concrete

3.5 FRAME AND COVER FOR METER VAULTS

A. Set cast iron frame in a mortar bed and adjust elevation of cover as follows:

1. In unpaved areas, set top of meter box or meter vault cover 2 to 3 inches above natural grade

2. In paved areas, set top of meter box or meter vault cover flush with adjacent concrete but no higher than 1/2-inch

3.6 BACKFILL

A. Provide bank run sand in accordance with Section 02315 – Excavation Trenching and Backfill for Utilities.

B. In unpaved areas, slope backfill around meter boxes and vaults to provide a uniform slope 1- to-5 slope from top to natural grade.

C. In paved areas, slope concrete down from meter box or vault to meet adjacent paved area.

END OF SECTION


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BLANK PAGE


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ADJUSTING MANHOLES, INLETS, AND VALVE BOXES TO GRADE 02086-1

SECTION 02086

ADJUSTING MANHOLES, INLETS, AND VALVE BOXES TO GRADE

PART 1 - GENERAL


A. Adjusting elevation of manholes, inlets, and valve boxes to new grades.

PART 2 - PRODUCTS

2.1 CONCRETE MATERIALS

A. Provide concrete, conforming to requirements of Section 03310 – Cast-in-Place Construction.

B. Provide precast concrete manhole sections and adjustment rings conforming to requirements of Section 02607 – Precast Manholes and Covers.

C. Provide grout conforming to requirements of Section 03605 – Nonshrink Grout.

2.2 CAST-IRON MATERIALS

A. Provide cast-iron materials conforming to requirements of Section 02607 – Precast Manholes and Covers.

2.3 PIPING MATERIALS

A. For riser pipes and fittings, refer to Sections 15106 – Ductile-iron Pipe and Fittings.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine existing structure, valve box, frame and cover or inlet box, frame and cover or inlet, piping and connections for damage or defects affecting adjustment to grade. Report damage or defects to Owner’s Representative.

3.2 ESTABLISHING GRADE

A. Coordinate grade related items with existing grade and finished grade or paving, and relate to established bench mark or reference line.

3.3 ADJUSTING MANHOLES AND INLETS

A. Rebuild adjustment portion of manhole or inlet by adding or removing Adjustments. Follow procedures for the type of structure being adjusted detailed in the following Sections:

1. Section 02607 – Precast Concrete Manholes

2. Section 03310 – Cast-in-Place Concrete

B. Salvage and reuse cast-iron frame and cover or grate.

C. Protect or block off manhole or inlet bottom using wood forms shaped to fit so that no debris or soil falls to bottom during adjustment.


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ADJUSTING MANHOLES, INLETS, AND VALVE BOXES TO GRADE 02086-2

D. Verify that manholes and inlets are free of visible leaks as result of reconstruction. Repair leaks in manner subject to Owner’s Representative’s approval.

3.4 ADJUSTING VALVE BOXES

A. Salvage and reuse valve box and surrounding concrete block as approved by Owner’s Representative. No separate pay.

B. Remove and replace 6 inch ductile iron riser pipe with suitable length for depth of cover required to establish adjusted elevation to accommodate actual finish grade.

C. Reinstall valve box and riser piping plumbed in vertical position. Provide minimum 6 inches telescoping freeboard space between riser pipe top butt end and interior contact flange of valve box for vertical movement damping.

D. After valve box has been set, aligned, and adjusted so that top lid is level with final grade.

3.5 BACKFILL AND GRADING

A. Backfill area of excavation surrounding each adjusted manhole, inlet, and valve box and compact according to requirements of Section 02315 – Excavation, Trenching, and Backfill for Utilities.

B. Grade ground surface to drain away from each manhole and valve box. Place earth fill around manholes to level of upper rim of manhole frame. Place earth fill around valve box concrete slab.

C. In unpaved areas, grade surface at uniform slope of 1 to 5 from manhole frame to natural grade. Provide minimum of 4 inches of topsoil. Provide seeding in accordance with Section 02936 – Topsoiling and Seeding, or if sodding in accordance with Section 02937 – Sodding.

END OF SECTION


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SITE CLEARING 02110-1

SECTION 02110

SITE CLEARING

PART 1 - GENERAL


A. Removal of surface debris.

B. Removal of paving, curbs, and sidewalks as required.

C. Clearance from site of plant life, underbrush and grass.

D. Excavation and stockpiling of topsoil.

E. Removal of miscellaneous other structures not covered by other sections.


A. Section 02060 - Demolition.

B. Section 01750 - Waste Material Disposal.

C. Section 02223 - Earthwork.


A. Conform to all codes and regulations for disposal of debris by all relevant governmental agencies.

B. Coordinate clearing Work with utility companies.

1.4 GUARANTY

A. Contractor shall guaranty that Work performed under this Section will not permanently damage adjacent work or facilities, and trees, shrubs, turf or plants designated to remain.

B. Should damage resulting from Contractor's operations become apparent during the period up to 18 months after final payment, Contractor shall be required to replace damaged items at no expense to Owner.

PART 2 - PRODUCTS

Not used.

PART 3 - EXECUTION

3.1 PREPARATION

A. Verify that existing plant life and features designated to be removed are tagged or identified.

3.2 PROTECTION

A. Protect utilities from damage.

B. Protect trees, plant growth, and features designated to remain as final landscaping.

C. Protect benchmarks and existing structures from damage or displacement.


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SITE CLEARING 02110-2

3.3 CLEARING

A. Clear areas required for access to site and execution of Work.

B. Remove paving, curbs, and sidewalks as required.

3.4 REMOVAL

A. Remove debris, rock and extracted plant life from site.

B. Excavate and stockpile topsoil from area of construction.

3.5 SCHEDULE - TREE REMOVAL

A. None.

END OF SECTION


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EROSION CONTROL AND RIPRAP

02112-1

SECTION 02112


PART 1 - GENERAL


A. Erosion and sediment control on the project site and on areas beyond the project limits which are affected by the project.


A. Section 02110 - Site Clearing.

B. Section 02211 - Rough Grading.

C. Section 02223 - Earthwork.

D. Section 02923 - Landscape Grading.

E. Section 02936 - Topsoiling and Seeding.

1.3 REGULATORY

A. Conform to all relevant governmental agency codes for soil erosion and sediment control during construction.

1.4 GENERAL

A. Contractor shall maintain the work site in a clean and orderly appearance and condition at all times.

B. All disturbed areas not designated for pavement and sidewalk replacement, structural use, and the like shall be stabilized.

1.5 STRUCTURAL PRACTICES

A. Contractor shall employ structural practices, as necessary, for erosion and sediment control during construction.

B. Such practices shall include clearing, grubbing and site preparation necessary for the construction of the specified practice.

C. As required, Contractor shall employ placement of stone; installation of filter cloth and silt fence; seeding; fertilizing; mulching and installation of erosion control matting.

D. Contractor shall be responsible for removal of structural practices when they are no longer required.

1.6 SUBMITTALS

A. Submit erosion control plan, products, vehicle and roadway cleaning procedure prior to construction. Submit weekly inspection reports of temporary erosion control system.


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02112-2

PART 2 - PRODUCTS

2.1 EROSION CONTROL MAT

A. Slopes greater than 3 to 1: mat manufactured by North American Green, SC 150 or approved equal.

2.2 SOIL STABILIZATION MAT

A. Channel bottom slopes up to 2:1, mat manufactured by North American Green, C 125 or approved equal.

2.3 FILTER FABRIC

A. Filter fabric shall be Trevira 1127, Mirafi 700X, or equal, installed in accordance with the manufacturer's instructions.

2.4 RIPRAP

A. Riprap shall be sound durable natural stone, D-50 = 8”, thickness of 12” (1.5D-50).

PART 3 - EXECUTION

3.1 EROSION CONTROL

A. The erosion control system shall protect adjacent properties and shall be reviewed by the Engineer. All erosion control measures shall be placed prior to commencement of grading.

B. Temporary measures shall be applied throughout the construction of the project to control erosion and to minimize siltation of adjacent property, street, drainage ditches, storm drains and waterways.

C. The Contractor shall employ all required erosion and sediment control measures whether indicated on the Drawings or mentioned in this Section or not mentioned.

D. Disturbed areas that are to be left unfinished for more than 30 days shall be seeded temporarily.

E. Stockpiled material shall be surrounded at the base with a temporary sediment barrier. Silt fences shall employ Mirafi 100X fabric or Poly Filter X fabric or approved substitute.

F. Slopes of stockpiled materials shall not exceed 2 to 1.

G. Vehicles leaving the construction site shall be cleaned to remove mud prior to entrance onto public rights of way. Washing shall be done on a temporary construction entrance specified hereinafter.

1. Stone used for the stabilized construction entrance and roadways shall be 2-1/2" crushed stone, unless a substitution is permitted by Engineer.

2. Contractor shall submit to Engineer for review, the method proposed for protecting public roadways from mud carried by vehicles leaving the construction site.

3. Contractor shall be responsible for continuous attention to this problem, and shall utilize another method if the first used method proves to be inadequate.


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02112-3

4. In the event that Contractor repeatedly fails to satisfactorily control mud deposition onto public roadways, the Owner reserves the right to employ outside assistance or to use Owner's own forces to provide the cleanup required.

5. The cost of such activity, plus related engineering costs, will be deducted from monies due the Contractor for other work.

H. Contractor shall be responsible for weekly inspection and submission of weekly reports to the Engineer of temporary erosion control system to insure maximum effectiveness of the protective measures. Any damaged areas of the erosion control system shall be immediately repaired.

I. Disposal of excavated material shall comply with all applicable Laws and Regulations.

J. Typical control measures.

1. Erosion Mat

2. Temporary gravel construction entrance

3. Construction road stabilization

4. Straw bale checks

5. Silt screens, fences

6. Storm Drain inlet protection

7. Temporary diversion dike

8. Temporary sediment basin

9. Outlet protection

10. Check dams

11. Topsoiling

12. Temporary seeding

13. Riprap

K. In the event that Contractor repeatedly fails to satisfactorily control erosion and siltation, the Owner reserves the right to employ outside assistance or to use Owner's own forces to provide the erosion control measures required.

The cost of such activity, plus related engineering costs, will be deducted from monies due the Contractor for other work.

3.2 RIPRAP

A. Riprap Placement:

1. The riprap shall be placed so that it produces a dense well-graded mass of stone with a minimum of voids.

2. Riprap shall be placed on filter fabric.


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02112-4

3. The desired distribution of stones throughout the mass may be obtained by selective loading at the quarry, controlled dumping of successive loads during final placing, or by a combination of these methods.

4. The riprap shall be placed to its full thickness in one operation, and shall not be placed in layers.

5. The riprap shall not be placed by dumping into chutes or similar methods which are likely to cause segregation of the various stone sizes.

6. Care shall be taken not to dislodge underlying material when placing the stones.

B. The finished slope shall be free of pockets of small stone or clusters of large stones.

1. Hand placing may be necessary to achieve the required grades and a good distribution of stone sizes.

2. Final thickness of the riprap blanket shall be within plus or minus 1/4 of the thickness specified.

3.3 MAINTENANCE

A. Throughout the construction period, Contractor shall inspect and maintain erosion and sediment control facilities, especially following rainfall events, to assure that they remain functional.

1. All accumulated sediment removed from erosion control facilities shall be disposed of properly.

B. Silt fences shall be replaced when "bulges" develop, when posts are knocked down or broken, and when fabric is torn or becomes undermined.

C. All fabric used shall be installed in accordance with manufacturer's recommendations.

D. Soil stabilization mat shall be designed to withstand velocities of 7 to 10 feet per second.

E. The mat shall extend under the riprap at channel ends per manufacturer's recommendations.

END OF SECTION


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ROUGH GRADING 02211-1

SECTION 02211

ROUGH GRADING

PART 1 - GENERAL


A. Removal of topsoil and subsoil.

B. Cutting, grading, filling, rough contouring, and compacting the site for site structures.

1.2 RELATED WORK

A. Section 02060 - Demolition.

B. Section 02110 - Site Clearing.

C. Section 02112 - Erosion Control and Riprap.

D. Section 02223 - Earthwork.

E. Section 02315 - Excavation, Trenching, and Backfilling for Utilities.

F. Section 02923 - Landscape Grading.


A. Submit Documents under provisions of Section 01781.

B. Accurately record actual locations of utilities remaining, rerouted utilities, and new utilities by horizontal dimensions, elevations or inverts, and slope gradients.

1.4 PROTECTION

A. Protect trees, shrubs, lawns, and other features remaining as portion of final landscaping.

B. Protect bench marks, fences, roads, sidewalks and paving and curbs.

C. Protect above or below grade utilities which are to remain.

D. Repair damage.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Topsoil: Excavated material, graded free of roots, rocks larger than one inch, subsoil, debris, and large weeds.

B. Subsoil: Excavated material, graded free of lumps larger than 3 inches, rocks larger than 3 inches, and debris.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Verify that survey benchmark and intended elevations for the Work are as indicated.

3.2 PREPARATION

A. Identify required lines, levels, contours, and datum.

B. Stake and flag locations of known utilities.


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ROUGH GRADING 02211-2

C. Locate, identify, and protect utilities that remain, from damage.

D. Notify utility company to remove and relocate utilities.

E. Protect above and below grade utilities that remain.

F. Protect plant life, lawns, and other features remaining as a portion of final landscaping.

G. Protect benchmarks, sidewalks, paving, and curbs from excavating equipment and vehicular traffic.

3.3 TOPSOIL EXCAVATION

A. Excavate topsoil from entire site and stockpile in area designated on site.

B. Do not excavate wet topsoil.

C. Cover topsoil stockpile to protect from erosion.

3.4 SUBSOIL EXCAVATION

A. Excavate subsoil from areas to be re-landscaped or re-graded.

B. Do not excavate wet subsoil.

C. When excavation through roots, perform work by hand and cut roots with a sharp axe.

D. Stockpile in area designated on-site to depth not exceeding 8 feet and protect from erosion. Remove from site, subsoil not being reused.

E. Stability: Replace damaged or displaced subsoil to same requirements as for specified fill.

3.5 TOLERANCES

A. Top Surface of Subgrade: Plus or minus one inch from required elevation.

END OF SECTION


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REMOVING EXISTING PAVEMENTS AND STRUCTURES 02221-1

SECTION 02221

REMOVING EXISTING PAVEMENTS AND STRUCTURES

PART 1 - GENERAL


A. Removing concrete paving, asphaltic concrete pavement, brick pavement and base courses.

B. Removing concrete curbs, concrete curbs and gutters, sidewalks and driveways.

C. Removing pipe culverts, sewers, and sewer leads.

D. Removing waterlines and water services lines including asbestos cement pipe per OSHA guidelines.

E. Removing existing inlets and manholes.

F. Removing and disposing of pre-stressed concrete beams and drill shafts.

G. Removing miscellaneous structures of concrete or masonry.

H. Removing existing bridge.

1. Removing existing wood and demolition debris.


A. Conform to applicable codes for disposal of debris.

B. Coordinate removal work with utility companies.

PART 2 - PRODUCTS – Not Used

PART 3 - EXECUTION

3.1 PREPARATION

A. Obtain advance approval from Owner’s Representative for dimensions and limits of removal work.

B. Identify known utilities below grade. Stake and flag locations.

3.2 PROTECTION

A. Protect following from damage or displacement:

1. Adjacent public and private property.

2. Trees, plants, and other landscape features designated to remain.

3. Utilities designated to remain.

4. Pavement and utility structures designated to remain.

5. Bench marks, monuments, and existing structures designated to remain.


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REMOVING EXISTING PAVEMENTS AND STRUCTURES 02221-2

3.3 REMOVALS

A. Remove pavements and structures by methods that will not damage underground utilities. Do not use drop hammer near existing underground utilities.

B. Minimize amount of earth loaded during removal operations.

C. Where existing pavement is to remain, make straight saw cuts in existing pavement to provide clean breaks prior to removal. Do not break concrete pavement or base with drop hammer unless concrete or base has been saw cut to minimum depth of 2 inches.

D. When street and driveway saw cut location is greater than one-half of pavement lane width, remove pavement for full lane width or to nearest longitudinal joint as directed by Owner’s Representative

E. Remove sidewalks and curbs to nearest existing dummy, expansion, or construction joint.

F. Where existing end of pipe culvert or end of sewer is to remain, install 8-inch-thick masonry plug in pipe end prior to backfill in accordance with requirements of Section 02316 – Excavation, Trenching, and Backfill for Utilities.

3.4 BACKFILL

A. Backfill of removal areas shall be in accordance with requirements of Section 02316 – Excavation, Trenching, and Backfill for Utilities and Section 02317 – Structural Excavation, Fill, and Backfill.

3.5 DISPOSAL

A. Inlet frames, grates, and plates; and manhole frames and covers, may remain City property. Disposal shall be in accordance with requirements of Section 01750 – Waste Material Disposal.

B. Remove from site, debris resulting from work under this section in accordance with requirements of Section 01750 – Waste Material Disposal.

END OF SECTION


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EARTHWORK 02223-1

SECTION 02223

EARTHWORK

PART 1 - GENERAL

1.1 SUMMARY

This Section includes the requirements for earthwork associated with the excavation of materials on site; excavation of borrow material from approved areas; compaction of natural subgrades; placement and compaction of embankments to grade; finish grading; stripping and stockpile and placement of topsoil; disposal of excess or unsuitable materials; and other required operations.

1.2 RELATED WORK

A. Quality Control. Section 01380.

B. Dewatering and Drainage of Excavation. Section 02240.

C. Excavation, Trenching and Backfilling for Utilities. Section 02315.

D. Structural Excavation, Fill and Backfill. Section 02317.

E. Trench Safety Systems. Section 02320.

F. Waste Material Disposal. Section 01750.

1.3 CLASSIFICATIONS

The following are brief definitions of classifications of earthwork.

A. Topsoil. Top 6 inches of natural surface soil possessing the characteristics of representative on-site soils which produce and sustain grass and other vegetative growth.

B. Stripping of Ground Surface. Stripping consists of removing all vegetation, decayed vegetable matter, rubbish and other unsuitable materials located within the areas designated for grading operations. Unless otherwise designated to remain, all areas shall be stripped to ground level prior to beginning earthwork.

C. Excavation. Consists of the required below-grade removal and proper utilization or disposal of every description and of whatever substances encountered within the grading limits of the project. Excavation shall be performed to the lines and grades indicated on the drawings.

D. Borrow. Material taken from approved areas to make up any deficit of excavated material.

E. Waste. Excavated material which is unsuitable for reuse on site or which is in excess of the materials needed for embankment operations.

F. Subgrade. Consists of that portion of the surface on which a compacted embankment or pavement is constructed.

G. Compaction. Compaction of soil materials consists of rolling, sprinkling, tamping and otherwise working the soil to achieve a percent of Standard Proctor density as determined by ASTM D 698.

H. Embankment. Earth fill placed and compacted in successive layers to the line and grade defined by the construction plans.

I. Finish Grading. Operations required for smoothing disturbed areas that are not overlaid with pavement or other structures. Finish grading consists of the final operations for bringing site grade to lines and grades shown on drawings.


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EARTHWORK 02223-2

PART 2 - PRODUCTS

2.1 MATERIALS

A. Earth Backfill.

1. Earth backfill shall be free of lumps, stones, trash and spongy or otherwise objectionable material and approved by the Engineer. Approved backfill material may be from the excavation or borrowed

B. Regular Backfill.

1. Where no other material is specified or shown, use suitable soils, from the excavation, that can be readily compacted to the specified densities. Do not use peat or other organic matter, silt, muck, debris, or material that cannot be compacted to specified tolerances.

C. Select Material.

1. Where select material/select fill is shown or specified, use lean clay and/or clayey sand (USCS Classification CL and/or SC), free of organic matter, foreign substances or rocks larger than 3 inches. When select material is not available on site, obtained select material from an approved off-site source. The material shall have a plasticity index between 10 and 20 as determined by ASTM D 4318 and a maximum liquid limit of 40 as determined by ASTM D 4318. Prior to bringing any of the proposed material to the site, submit for review an analysis of the proposed material, including a moisture-density relationship curve prepared in accordance with ASTM D 698 by a certified independent testing laboratory employed and paid by the Contractor.

2. The Contractor shall reconfirm the suitability of the off-site fill by testing in accordance with ASTM D 4318 at a minimum rate of one test per 500 cubic yards of placement. These tests shall be performed by a certified independent testing laboratory employed and paid by the Contractor.

D. Topsoil.

1. Obtain topsoil from site or provide natural fertile, friable loam suitable for growths of grass and plants.

2. Topsoil shall contain decomposed vegetable matter, finely divided and minimum 4 percent by weight.

3. Topsoil shall be free from subsoil, clay, brush, weeds, rocks and dirt clods larger than 1 inch in diameter, stalks, roots and materials that would be toxic or harmful to growth.

2.2 EQUIPMENT

Contractor shall furnish, operate and maintain appropriate equipment necessary to achieve uniform layers, sections and smoothness in grade and to meet specified compaction densities.

PART 3 - EXECUTION

3.1 VERIFICATION OF CONDITIONS

Contractor shall inform and satisfy himself as to the character, quantity and distribution of material to be excavated.

3.2 TOPSOIL REMOVAL

A. Prior to excavation or embankment activities, topsoil located within clearing limits shall be stripped to depths encountered but no less than 3 inches in depth.


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EARTHWORK 02223-3

B. Stripped topsoil shall be transported and deposited in stockpiles convenient to areas receiving topsoil.

C. Topsoil shall be kept separate from other excavated materials, brush, litter, weeds, stones larger than 2 inches in diameter and other materials that would interfere with planting and maintenance operations.

D. Protect stockpiled topsoil from dumping of unwanted material and dumping by the public.

E. The topsoil source and stockpile areas shall be graded to drain as far as practical during the periods of removal and storage.

3.3 EXCAVATION

A. Construction Methods.

1. Perform excavation of all types of materials encountered within limits of project to the lines, grades and elevations indicated in the plans.

2. All excavated materials shall be unclassified and no extra compensation shall be made based on types of materials encountered.

3. Materials approved by the Engineer shall be used in the formation of embankments or otherwise utilized or disposed of. Unsatisfactory and/or excess materials shall be considered waste materials and shall be disposed of per Section 01750, Waste Material Disposal.

4. If it is not possible to place material in the proper section of permanent construction at the time of excavation, stockpile the material in approved areas for later use. Stockpiled materials should be protected from dumping of unwanted materials and dumping by the public.

B. Blasting. Use of explosives for excavation operations should not be necessary and will not be permitted.

C. Drainage. During excavation, maintain grades for complete drainage. As necessary, install temporary drains or drainage swales to intercept or divert overland flow from excavated areas. Ponding in the excavation and seepage from groundwater shall be removed per Section 02240, Dewatering and Drainage of Excavation.

D. Existing Utilities. Contractor shall field verify locations of existing utilities prior to extensive excavation operations. While it is the intent of the construction plans to show the known locations and sizes of existing utilities, the Engineer retains no responsibility for lines not shown on construction plans or known to the Contractor prior to excavation. Contractor shall protect existing utilities from damage during excavation. Any damage to existing utilities shall be reported immediately and shall be satisfactorily repaired.

E. Pipelines. Contractor shall suspend machine excavation within 5 feet of any pipeline right-of-way until a company representative is present to identify pipe location and to direct further excavation operations. Notification of pipeline company of Contractor's operations and request for attendance of a representative will be Contractor's responsibility. Contractor shall resume suspended operations only under supervision of pipeline company representative and employ only such excavation methods, means, equipment and safety measures as approved by representative. Contractor shall do no work on pipeline as part of this contract, such as lowering, cribbing up, construction of bents, repairs to coating, cutting, welding, making repairs or other essential work, all of which will be done by pipeline company and at their own expense. Contractor shall be solely responsible to pipeline company for any damages to their line and any related construction as a result of Contractor's operations, irrespective of any order, directive or approval by company representative, or of his presence on the work. The Contractor will


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EARTHWORK 02223-4

not be reimbursed directly for any extra work or expenditure as a result of intersecting any pipeline installation.

3.4 EXTRA EXCAVATION

A. Upon completion of excavation to the lines and grades given on the construction plans, areas identified as having weak or poor soil characteristics shall require extra excavation. Contractor shall remove soft or undesirable materials to a depth of 18 inches and backfill areas with stable fill material. Fill material shall comply with requirements for select material and shall be compacted to specified density per Compaction paragraphs within this section.

B. The removal and replacement of unsatisfactory material shall be measured and paid for in compliance with the provisions of the General Conditions.

3.5 SUBGRADE UNDER PAVEMENTS

A. Provide treated subgrade under pavement as shown on Drawings. If subgrade requirements are not shown, treat subgrade as follows:

a. Strip topsoil and/or remove pavement as applicable. b. Mix/place new or existing subgrade material to achieve grade as required. c. Proof roll subgrade by two passes in each direction with a 15 ton pneumatic roller

and remove soft areas to a depth of 18 inches, replace with stable fill material. d. After proof rolling, scarify and thoroughly mix lime and upper 6 inches of

subgrade material. e. Let lime treated subgrade sit for 1 to 4 days. f. Compact lime treated subgrade to 95% while maintaining moisture at 1% to 3%

above optimum moisture content. g. Cure lime treaded subgrade either by moist curing per TxDOT Item 204

“Sprinkling” or by applying asphalt material (0.05 to 0.20 gal/syd), minimum curing time of 5 days prior to placement of concrete pavement.

3.6 TREATMENT OF NATURAL SUBGRADE UNDER EMBANKMENTS

A. After clearing and grubbing and excavation to lines under proposed embankments, proof roll and remove soft or undesirable material to a depth of 18 inches. Break down sides of holes or depressions to flatten the slopes.

B. Fill each depression with the regular backfill. Place the fill in layers moistened and compacted as specified in this section.

C. After depressions have been filled and immediately before placement of compacted fill in a section of the embankment, thoroughly scarify the foundation material to a depth of 6 inches. Remove roots and debris turned up while loosening the soil.

D. Compact the surface of the embankment subgrade as specified in this section.

E. Take care to prepare the embankment so that planes of seepage or weakness are not induced. Should the Owner’s representative suspect such a deficiency, the material must be thoroughly broken and recompacted before proceeding with construction.

3.7 EMBANKMENT

A. Inspection of Subgrade. Do not place fill on any part of the embankment subgrade until the subgrade preparation has been inspected by the Owner's representative.

B. Spreading Fill. After dumping material, break up and spread fill material. During dumping and spreading process, remove all roots, stones and debris that are uncovered in the embankment material. Construct embankments in successive horizontal layers, extending across the entire fill area. Each layer of fill shall be no greater than 8 inches in depth and shall be uniform as to material and moisture content before compaction. Individual lifts shall be scarified after compaction to prevent development of laminations


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EARTHWORK 02223-5

between lifts. As soon as possible after placement begins, crown the surface to drain freely and maintain such conditions throughout construction.

C. Benching. When fill is to be made and compacted against hillsides and/or existing fill, the slopes of original hillside and/or fill shall be horizontally benched to key the fill material to the underlying ground. A minimum of 6 inches normal to the original slope shall be scarified and recompacted, as the fill is brought up in layers, to ensure that the new work is constructed on firm subgrade. This subsection applies to existing slopes having a steeper than 4:1 gradient.

D. Compaction. Compact each lift to required density by blading and rolling with suitable equipment. Use mechanical tamps to obtain required density in inaccessible areas. Compact to 98 percent of maximum laboratory dry density as determined by the Standard Proctor compaction test AASHTO Test Method T99 (ASTM D 698). Compaction testing shall be every 2,500 square feet per lift.

E. Moisture Control. Compaction shall be completed to the required maximum density obtainable with the natural moisture of the embankment material wherever possible. However, the moisture content shall not vary from the optimum, as determined by AASHTO Test Method T99 (ASTM D 698) by more than 1 to 3 percent. Adjust wetter than optimal materials by spreading and drying. This process may be assisted by disking or harrowing if necessary. Adjust dryer than optimal materials by sprinkling layer with water and working moisture into soil by harrowing or other approved method.

3.8 DISTRIBUTION OF TOPSOIL

See Specification Section 02936, Topsoiling and Seeding.

3.9 FINAL GRADING

A. After other work has been completed except for exactness of finish as required, all surfaces shall be smoothly shaped.

B. Ditches and channels shall be cleared of debris and obstructions.

C. Excess earth or other waste material adjacent to structures, poles, trees or other objects shall be leveled down or otherwise disposed of as required.

D. Loose stones, rocks and boulders within the project site that would fail to pass a 2-inch ring shall be removed and disposed of as required.

E. Roots, trash and other debris shall be removed from Owner's controlled land.

F. Dragging, pushing or scraping of material along or across the surface of completed pavement will not be permitted.

G. Continuously maintain sections until acceptance of work.

H. Finish surface not more than 0.10 feet above or below established grade or cross section.

I. Finish ditches and gutters to drain readily.

J. Where existing grade is disturbed in areas not marked to be graded, re-grade disturbed area to original grade.

3.10 TESTING

A. Laboratory Services. Owner shall appoint a commercial testing laboratory to assess adequacy of materials and compaction as outlined in Section 01380, Quality Control.

B. Testing Requirements.

1. Prepare optimum moisture/density relationship for subgrade in accordance with AASHTO T99 (ASTM D 698).


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EARTHWORK 02223-6

2. Test compacted general fill embankment and backfill as follows:

a. One field density test minimum for every 1000 cubic yards of material placed in compliance with ASTM D 1556 or D 2922.

b. Four random field density tests minimum of backfill at each culvert, abutment and similar locations in compliance with ASTM D 1556 or D 2927.

END OF SECTION


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DEWATERING AND DRAINAGE OF EXCAVATION

02240-1

SECTION 02240


PART 1 GENERAL

1.1 SUMMARY

A. This section provides for furnishing all labor, materials, equipment, power and incidentals, and for performing all operations necessary to dewater, drain and maintain excavations and foundation beds as described herein and as necessary for construction of structures and appurtenances. Included are construction, maintenance and removal of cofferdams; installing, maintaining, operating and removing well point systems and other approved devices for lowering water table within an excavation; removal of standing water, surface drainage and seepage from excavation or other work, and protecting work against rising waters and floods, and repair of any resulting damage.

B. The Contractor shall assume sole responsibility for dewatering systems and for all loss or damage resulting from partial or complete failure of protective measures.

1.2 RELATED WORK

A. Excavation, Trenching and Backfilling for Utilities. Section 02315.

B. Structural Excavation, Fill, and Backfill. Section 02317.

C. Trench Safety Systems. Section 02320.

1.3 SUBMITTALS

Submit certification letter sealed by a Professional Engineer registered in the State of Texas that methods of dewatering, foundation drainage and diversion have been designed in accordance with sound engineering practice.

A. Well Point System. Show the well point system in clear detail, including the pump capacity, or other proposed method for lowering the water table within the areas where the concrete structures, compacted fill and backfill are to be constructed.

B. Equipment Supplier. Name the supplier of well point or other foundation drainage equipment.

C. Review. Do not start dewatering or other foundation drainage until plans and other data required in this paragraph are reviewed.

PART 2 PRODUCTS

2.1 MATERIAL

A. Select equipment and material desired.

PART 3 EXECUTION

3.1 DEWATERING EXCAVATIONS

A. Furnish, install, operate and maintain all necessary pumping for dewatering the various parts of the work and for maintaining free of water the foundations and such other parts of the work as required for construction operations. Also, as required for inspections and safety, or for any reason determined by the Engineer to be desirable.

B. Continue dewatering in all required areas, until the concrete structure or the embankment have been completed to the top of the slopes of the excavation, or to another designated level.


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02240-2

C. Provide a uniform diameter for each pipe drain run constructed for dewatering. Remove the pipe drain when it has served its purpose. If removal of the pipe is impractical, provide grout connections at 50-foot intervals, and fill the pipe with clay grout or cement and sand grout when the pipe has served its purpose.

D. After completion of construction at the site, remove the cofferdams and dispose of the material.

E. Replace any excavation performed for convenience in the foundation beds with materials as impermeable as the original foundation material, and compacted to not less than 95 percent maximum density.

3.2 DRAINAGE OF FOUNDATION BEDS

A. Dewater foundation beds for concrete structures by using well points or another approved method. Maintain the saturation line at least 2 feet below the lowest elevations where concrete or embankment is to be placed. Dewater foundation beds for embankments or scour protection so that the surface on which the materials are to be placed will be dry and firm.

B. Drain foundations in areas where concrete is to be placed before placing reinforcing steel. Keep foundation beds free from water for 3 days after concrete is placed.

C. Produce a downward seepage of water through the sandy materials in the foundation beds, promoting their compaction as the water table drops. Be prepared to demonstrate that the method proposed will produce the desired results. Be prepared to adopt other means of obtaining these effects if the proposed method fails.

3.3 REQUIREMENTS FOR WELL POINTS

A. Well points, where used, must be furnished, installed and operated by a reputable contractor regularly engaged in this business, and approved.

B. Submit the design of the well point system for review. Predrain by well point vacuum method.

C. Install sufficient piezometers to show that all trench excavation in sandy material is predrained prior to excavation.

D. Well points may be omitted for portions of underdrains or other trenches, only where auger borings and piezometers show that the soil is predrained by an exterior system.

3.4 DURATION OF DRAINAGE

A. In areas where concrete is to be placed, carry out the foundation drainage so that the required lowering of the water table will be effected prior to placing reinforcing steel. Keep foundation beds free from water to the same levels for 3 days after pouring concrete.

B. Operate pumps to keep each underdrain system drained to the approximate level of the top of the lowest pipe of the system until the removal or flooding of cofferdams. Pipe manholes are provided for this purpose adjacent to the structures.

3.5 COFFERDAM REQUIREMENTS

A. Provide a suitable cofferdam for each excavation where necessary to control water, so the foundation can be placed dry. Also provide a suitable cofferdam to prevent sliding and caving of walls of the excavation.

1. Where no ground or surface water is encountered, the cofferdam only need be sufficient to protect workmen and to avoid having cave-ins or slides extend beyond the limits of the excavation, as drawn.


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02240-3

2. Provide cofferdams with enough clearance for the construction and removal of any required forms, for the inspection of their exteriors, and to permit pumping outside the forms.

B. Extend sheet piling cofferdams well below the bottom of footings. Brace the piling well and make as watertight as possible.

3.6 FLOODING AND REMOVAL OF COFFERDAMS

A. Provide for admitting water gradually behind the cofferdam to equalize the water level on the two sides of the cofferdam before it is flooded or breached.

B. Use this feature before the cofferdam is removed, and in the event of a flood that could overtop the cofferdam.

C. Do not breach cofferdams where the water level differential is more than 2 feet between the two sides of the cofferdam, unless the water depth on the high side is no more than 3 feet at the point of breaching.

3.7 PROTECTION OF STRUCTURES

A. Provide adequate protection for all structures to avoid damage to concrete.

B. Operate construction equipment over completed concrete slabs or structures only with approval. Rubber tire equipment heavier than 5 tons and crawlers heavier than 7 tons will require adequate load spreading by sand fill or other means.

3.8 REPAIR OF DAMAGE

A. Assume full responsibility for all loss and damage due to flood, rising water or seepage in any part of the work. Repair any damage to partially completed work from these or other causes, including the removal of slides, repair of foundation beds and performance of any other work necessitated by failure or slippage of cofferdams or lack of adequate dewatering or drainage facilities.

END OF SECTION


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02240-4

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EXCAVATION, TRENCHING AND BACKFILLING FOR UTILITIES 02315-1

SECTION 02315

EXCAVATION, TRENCHING AND BACKFILLING FOR UTILITIES

PART 1 - GENERAL

1.1 SUMMARY

This Section includes the furnishing all equipment, materials and labor for excavation, trenching and backfilling for storm sewers, water distribution mains, sanitary sewers and other utility systems and appurtenances.

1.2 RELATED WORK

A. Dewatering and Drainage of Excavation. Section 02240.

B. Earthwork. Section 02223

C. Structural Excavation, Fill and Backfill. Section 02317.

D. Trench Safety Systems. Section 02320.

E. Ductile Iron Pipe and Fittings. Section 15106.

PART 2 - PRODUCTS

2.1 EARTH BACKFILL

A. As defined in Section 02223 – Earthwork.

2.2 SAND

A. As defined in Section 02317 – Structural Excavation, Fill, and Backfill.

PART 3 - EXECUTION

3.1 EXCAVATION

A. Procedure. Excavate to indicated or specified line and grade.

1. Excavate by open cut with trenching machine or backhoe. Do not use excavated material composed of large chunks or clods for backfill, but dispose of such material and provide other suitable material for backfill without additional expense.

2. During excavation, pile material suitable for backfilling in an orderly manner far enough from the bank of the trench to avoid overloading, slides or cave-ins.

3. Remove from site or waste as indicated all excavated materials not required or suitable for backfill. Loading and transportation of waste material shall be included in bid price and no additional payment will be made.

4. Grade as necessary to prevent surface water from flowing into trenches or other excavations.

B. Trench Excavation.

1. Cut banks of pipe trench as nearly vertical as practical in the pipe zone without violating the provisions of Section 02320 – Trench Safety System. Remove stones as necessary to avoid point-bearing. Over excavate wet or unstable soil from the trench bottom to permit construction of a more stable bed for pipe.

2. Dig the trench the proper width as shown. If the trench width below the top of pipe is wider than specified in this section or shown on the plans, then the Contractor shall install higher class of pipe and/or improved bedding as determined by the Engineer. No additional payment will be made.


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3. Accurately grade the trench bottom to provide uniform bearing and support for each section of pipe on undisturbed soil at every point along its entire length, except where necessary to excavate for bell holes and for proper sealing of pipe joints. Dig bell holes and depressions for joints after the trench bottom has been graded. Make bell holes and depressions for joints no deeper, longer or wider than needed to make the joint properly.

4. If any excavation is carried beyond the lines and grades required or authorized, the Contractor shall, at his own expense, fill such space with concrete or other suitable material as directed by the Engineer. No additional payment will be made.

5. The excavation of trench shall not advance more than 100 feet ahead of the completed pipe work except where specifically authorized by the Engineer.

C. Sheeting and Bracing.

1. Install, in sewer trenches and other excavations with vertical sides, sheeting and bracing necessary to support the sides. Sheeting and bracing shall be so installed as to place no undue or damaging strain on uncompleted work. Any damage resulting from settlement or lack of bracing shall be repaired by the Contractor at his own expense.

2. The sides of all trenches shall be securely held by bracing and sheeting which may be removed in units when the level of backfilling has reached the elevation necessary to properly protect the work and adjacent property.

3. When sheeting or shoring cannot be safely removed, it shall be left in place. Timber left in place shall be cut off at least 2 feet below the surface.

4. Payment for sheeting and bracing trenches shall be included in the trenching, laying and backfilling item. No additional payment shall be made.

5. The Contractor shall comply with the provisions of Section 02320 – Trench Safety Systems.

D. Pipe Zone. The pipe zone is defined as including the pipe bedding, backfill to one-half the pipe diameter (to the springline) and the initial backfill to 12 inches above the top of the pipe.

E. Pipe Bedding.

1. Accurately grade the bottom of the trench 6 inches below the elevation of the normal pipe installation and limit clear space on either side of the pipe to 6 inches at and below the top of the pipe. Place and compact 6 inches of sand in the trench before the pipe is laid. Install the pipe and place additional sand. Compact around the pipe to a height 12 inches above the top of pipe. Compact to a minimum density of 95 percent using AASHTO Standard Method T-99.

2. All embedment for pipes under structures or shall be concrete encased as shown on the drawings.

3. Density testing frequency shall be every 500 linear feet, except under paving or structures where the test frequency shall be every 150 linear feet.


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F. Water in Excavation. The Contractor shall, at all times, take such precautions as are necessary to keep the work free from ground or surface water. Pumps of adequate capacity or other approved method shall be provided to remove water from the excavation in such a manner that it will not interfere with the progress of the work or the proper placing of other work. Water shall be discharged in a manner approved by the Engineer. Ground or surface water will not be allowed to drain into or be pumped into an existing sanitary sewer system. If the work includes connection to an existing sanitary sewer, a temporary watertight plug must be installed and maintained within the pipe for the duration of the contract and bedding material interrupted in a manner approved by the Engineer to isolate new construction from the existing system. All costs of handling the water shall be included in the bid item and no additional payment shall be made. If necessary, well points should be used. Refer to Section 02240 – Dewatering and Drainage of Excavation.

3.2 UTILITY INSTALLATION

A. Storm and Sanitary Sewers. Limit clear space on either side of the pipe as per bedding requirements. Above the pipe, cut as wide as necessary to sheet and brace and properly perform the work. Provide bedding as shown on drawings and specified in this section.

B. Electrical System. Banks of trenches for electrical cables and duct lines need not be kept vertical but may be sloped or widened to such general limits as may be set, provided there is no interference with other utilities. Special trenching requirements for conduits, direct-buried electrical cables and duct lines are specified in Division 16 - Electrical.

C. Excavation of Appurtenances. Excavate sufficiently for manholes and similar structures to leave at least 2 feet clear between the outer surfaces and the embankment or timber that may be used to hold and protect the banks. Any over-depth excavation below such appurtenances not directed will be considered unauthorized and will be refilled with sand, gravel, cement-sand or concrete, as directed, at no additional cost.

3.3 POTENTIAL OBSTRUCTION INVESTIGATION

A. The horizontal and vertical location of the various underground lines shown on the Contract Drawings, including but not limited to water mains, storm sewers, sanitary sewers, telephone lines, electric lines or power ducts, pipelines, concrete and debris, are based on the best information available but are only approximate locations. Therefore, at the locations shown on the drawings, the Contractor shall field verify the horizontal and vertical locations of such lines within a zone 2 feet vertically and 4 feet horizontally of the proposed work. The Owner and Engineer will endeavor to familiarize the Contractor with all known utilities, obstructions and potential obstructions. The Contractor is urged to use extreme caution and care when uncovering these lines. Any damage to known or unknown utilities or obstructions occurring during the "Potential Obstruction Investigation" will be the full responsibility of the Contractor.

B. Prior to the actual field verification phase, the Contractor shall notify all utility companies involved of the date and time that the investigation excavation will occur and request that their respective utility lines be marked in the field. If any utility or pipeline company requires their representative to be present during excavation, the Contractor shall comply with that request. The Contractor shall provide the Engineer with 48 hours notice prior to any field excavation or related work.

C. Once the known, unknown or potential obstructions have been uncovered, their vertical and horizontal locations shall be surveyed by the Contractor relative to the project baseline and datum and plotted on a 11″ x 17″ copy of the Construction Drawings.

D. The 11″ x 17″ Construction Drawing with the plotted utility or obstruction location will then be submitted to the Engineer and titled "Potential Obstruction Report" before or simultaneous with the pipe shop drawing submittal.


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E. The Engineer shall promptly review the "Potential Obstruction Report" and approve the construction as designed or modify the design as required. The Contractor will be promptly notified of any design modifications.

3.4 PROTECTION OR REMOVAL OF UTILITY LINES

A. The Contractor shall anticipate all underground obstructions such as, but not limited to, water mains, gas lines, chlorine gas lines, storm and sanitary sewers, telephone or electric light or power ducts, concrete, and debris. These lines or obstructions indicated on the drawings must be verified in the field by the Contractor. The Owner and Engineer will endeavor to familiarize the Contractor with all known utilities and obstructions, but this will not relieve the Contractor from full responsibility in anticipating all underground obstructions whether or not shown on the drawings.

B. The Contractor shall, at his own expense, maintain in proper working order and without interruption of service all existing utilities and services which may be encountered in the work, except that with the consent of the Engineer such service connections may be temporarily interrupted to permit the Contractor to remove designated lines or to make temporary changes in the location thereof as will aid in the completion of the work and at the same time maintain service to the property so originally benefitted. The cost of making any temporary changes shall be at the Contractor's expense as no additional payment will be made.

C. Before starting construction, the Contractor shall notify all utility companies involved to have their utilities located and marked in the field. All underground utilities shall then be uncovered to verify location and elevation before construction begins. The Contractor shall obtain all necessary permits.

3.5 BACKFILLING

A. Criteria. Backfill trenches to within 4 inches of ground surface with embankment fill as specified under Section 02223 – Earthwork. The remaining backfill will consist of topsoil in accordance with Section 02223 – Earthwork. Reopen trenches improperly backfilled to depth required for proper compaction. Refill and recompact as specified, or otherwise correct the condition in an approved manner.

B. Open Areas.

1. In the pipe zone, place backfill evenly and carefully around and over pipe in layers no thicker than 6 inches. Compact with mechanical hand tampers to 95 percent AASHTO Density, Test Method T-99, until there is a cover of not less than 1 foot over utility lines. Use selected backfill material of optimum moisture content. Take special care not to damage pipe wrapping or coating.

2. Above the pipe zone, deposit backfill in 8-inch layers. Compact each layer to 90 percent AASHTO Density, Test Method T-99.

3. All forms, lumber, trash and debris shall be removed from manholes and other structures. Backfill shall be placed symmetrically on all sides in layers no thicker than 8 inches. Each layer shall be compacted to 90 percent AASHTO Density, Test Method T-99.

C. Pavement Sections.

1. In the pipe zone, deposit backfill material in layers 6 inches or thinner. Compact each layer to 95 percent of AASHTO Density, Test Method T-99.

2. Above the pipe zone, backfill soil material to be deposited in 8-inch layers, each layer compacted to 95 percent AASHTO Density, Test Method T-99. Place compacted material to within 0.5 feet of finished pavement surface.


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3. Use cement-sand backfill above the pipe zone only when directed or as shown on plans. Deposit cement-sand in 12-inch layer within 4 hours of mixing and compact to 95 percent AASHTO Density, Test Method T-99. Cure cement-sand layer at least 3 days before placing pavement on top of it.

D. The density testing frequency shall be every 500 linear feet per layer, except under paving or structures where the density testing frequency shall be every 150 linear feet per layer.

3.6 TEST FOR DISPLACEMENT OF SEWERS

A. After the trench has been backfilled to 2 feet above the pipe and tamped as specified, check the alignment as follows. Flash a light through the sewer between manholes or process units. Use a flashlight or reflect sunlight with a mirror. If the illuminated interior of the pipeline shows poor alignment, pipe displacement or other defects, correct to the satisfaction of the Engineer.

B. All plastic pipe shall be tested for deflection by hand-pulling a mandrel with an outside diameter equal to 95 percent of the original inside diameter of the pipe through the pipe after backfilling is complete. Mandrel is to be pulled by hand line. Should the mandrel meet any resistance, the Contractor may clean the line, or correct the resistance, and repeat the test. Any pipe not meeting this test shall be removed and replaced at the Contractor's expense.

END OF SECTION


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BLANK PAGE


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STRUCTURAL EXCAVATION, FILL AND BACKFILL 02317-1

SECTION 02317

STRUCTURAL EXCAVATION, FILL AND BACKFILL

PART 1 - GENERAL

1.1 SUMMARY

This section describes requirements for:

A. The excavation for all structures including equipment foundations and slabs on ground, backfilling around completed structures and the disposal of all excess excavated material. All operations required for the proper completion of the excavation work, including sheeting, shoring and bracing, dewatering of excavations and compaction of backfill are included.

B. All structural fill required for completion of the work as shown or specified.

C. Trenching and backfilling for all utilities under structures.

D. Compacted sand cushion under slabs on ground.

E. Filter material for foundation drains.

1.2 RELATED WORK

A. Quality Control. Section 01380.


C. Cast-in-Place Concrete. Section 03310.

1.3 REFERENCE STANDARDS

A. American Society for Testing and Materials (ASTM).

1. ASTM C 33 - Standard Specification for Concrete Aggregate.

2. ASTM C 136 - Standard Method for Sieve Analysis of Fine and Coarse Aggregates.

3. ASTM D 698 - Test Method for Laboratory Compaction Characteristic of Soil Using Standard Effort [12,400 ft-lbf/ft (6,000 KN-m/m)].

4. ASTM D 2487 - Standard Test Method for Classification of Soils for Engineering Purposes.

5. ASTM D 4253 - Standard Test Method for Maximum Index Density and Unit Weight of Soils Using a Vibrating Table.

6. ASTM D 4254 - Standard Test Method for Minimum Index Density and Unit Weight of Soils and Calculation of Relative Density.

7. ASTM D 4318 - Standard Test Method for Liquid Limit, Plastic Limit and Plasticity Index of Soils.

1.4 SUBMITTALS

A. Testing laboratory reports to show compliance with specifications for material from off-site locations. The specified tests shall be performed by a certified independent testing laboratory employed and paid by the Contractor.

B. Submit details of any proposed dewatering system for review prior to installing the dewatering system. Review and acceptance by the Engineer will not relieve the Contractor of any responsibility for the adequacy of the dewatering system.


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1.5 PROTECTION OF FACILITIES

A. Before the start of earthwork operations, adequately protect existing structures, utilities, trees, shrubs and other permanent objects. Costs resulting from damage to permanent facilities due to negligence or lack of adequate protection will be charged to the Contractor. The Contractor will also be charged for damage to facilities scheduled for later removal or demolition if the damage sufficiently impairs proper operation to the extent that temporary replacement or repair is required. Prior to beginning of the project, a joint inspection will be made by the Engineer and Contractor to determine the condition of any existing structures or other permanent objects.

B. Provide surface drainage during the period of construction to protect the work and to avoid nuisance to adjoining property. Comply with all applicable requirements of the Federal Clean Water Act and all state and local ordinances for disposal of surface drainage.

C. The Contractor shall conduct his operations in such fashion that trucks and other vehicles do not create a dirt nuisance in the streets. The truck beds shall be sufficiently tight, and shall be loaded in such a manner that objectionable materials will not be spilled onto the streets. Any dirt, mud, or other materials that are spilled onto the streets or deposited onto the streets by the tires of vehicles shall be promptly cleared away by the Contractor.

1.6 BLASTING

Blasting will not be permitted.

1.7 TESTING LABORATORY SERVICES

A. The Contractor shall employ and pay for the services of an independent testing laboratory, as specified in Section 01380, Quality Control, to perform compaction tests on the compacted material. The Contractor shall cooperate with the testing laboratory in performing these tests. The Contractor shall notify the laboratory at least 48 hours in advance of the time at which tests will be required. Any area failing to comply with the specifications shall be reworked as required to conform to the specifications.

B. Frequency of in-place field density testing shall be as follows:

1. Fill and Backfill. One test per lift per 1,000 square feet.

2. Subgrade, Existing Ground. One test per 1,000 square feet.

1.8 INSPECTION OF EXCAVATIONS

A. Notify the Owner’s representative at least 24 hours prior to completion of any excavation so that the Owner’s representative may inspect the excavation. Do not place reinforcing steel or concrete in the excavation prior to inspection unless the Engineer has given approval to proceed without inspection.

B. Notify the Owner’s representative at least 48 hours prior to backfilling of pipe trenches. Do not begin backfilling of pipe trenches until all pipe joints have been inspected and approved unless the Engineer has given approval to backfill the trenches without inspection.

PART 2 - PRODUCTS

2.1 REGULAR MATERIAL



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2.2 SELECT MATERIAL


B. Backfill under or against new work shall be select material unless noted otherwise.

2.3 OFF-SITE MATERIAL

Any soil brought to the site from off-site locations shall not be contaminated. The material shall not contain more than 100 ppm TPH (total petroleum hydrocarbons) and not more than 30 ppm total BTEX (benzene, toluene, ethylbenzene, xylene). The Contractor shall have the material from each off-site location tested, at his expense, by an analytical laboratory. The laboratory report shall be submitted for review prior to bringing any of the material on-site.

2.4 SAND

Use sand that is free from clay lumps, organic and other deleterious material, and having a plasticity index of 12 or less.

2.5 CONCRETE BACKFILL

Concrete backfill shall conform to Class B (2500 psi) concrete as specified in Section 03310, Cast-in-Place Concrete.

PART 3 - EXECUTION

3.1 CLEARING

A. Remove shrubs, trees, stumps, roots, underbrush, weeds and other vegetation in the way of new construction. Remove any existing structures, paving or foundations in the way of the new construction.

B. Strip soil and vegetation at areas of new structures and slabs to a 6-inch minimum depth or deeper as required to remove all vegetation, roots or other organic matter.

C. Topsoil consisting of friable material free of vegetation, clay lumps, stones or toxic substances shall be stockpiled in areas, as directed by the Owner’s representative, at the site for use in finish grading.

3.2 SLABS ON SOIL

A. Structural Foundations. Excavate to a minimum of 12 inches below the bottom of the slab or deeper if required on the plans to remove all organic material. The excavation shall extend for a minimum of 3 feet outside the slab perimeter unless shown greater on the plans. Proof-roll the excavation to detect any soft or wet spots. Replace any soft or wet spots and fill any depressions from stump or rock removal with compacted select material.

B. Building Slabs on Grade.

1. Backfill excavation to 6 inches below the bottom of the slab with compacted select material. Backfill shall begin as soon as possible after excavation has been completed so as to maintain the in situ moisture content of the subgrade. Place select material in uniform layers of loose material, 6 to 8 inches in depth, dried or moistened as required to obtain optimum moisture content to within +4 percent to -2 percent and compact each layer to 95 percent maximum density as determined by ASTM D 698.

2. Final grading to required lines and grades under the slab shall be a 6-inch layer of compacted sand. Final grading around the perimeter shall be select material with topsoil.


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C. Compaction.

1. The methods used to secure the specified compaction and moisture content will be the Contractor's responsibility. Wet soils shall be worked by plowing, disking, or scarifying and air drying as required to reduce the moisture content to optimum levels. The Contractor may, at his option, add flue dust or other drying material acceptable to the Engineer to speed up the drying procedure at no change in the contract sum.

2. The compacting equipment and method of compaction shall be such that uniform density will be obtained over the entire area and depth of material being compacted. All fill materials deposited in place by scrapers, dump trucks, drag lines or similar equipment shall be thoroughly broken up before spread into uniform layers.

3. Where partially completed or completed compacted areas are disturbed by subsequent construction operations or adverse weather, or if the compacted areas have been exposed to the weather such that it is no longer at its optimum moisture content, scarify the surface, reshape and compact to required density prior to further construction.

3.3 EXCAVATION

Excavation work shall be unclassified and includes removal of all types of material encountered without exception. Make excavations to lines and grades indicated on drawings. Complete excavations within the tolerances specified. Comply with all federal, state and local safety requirements.

A. Sheeting, Shoring and Bracing.

1. Excavation for construction of underground structures shall either have sloped sides to prevent sloughing and cave-ins or provide sheeting, shoring and bracing of the excavations to properly and safely complete the work. Construct sheeting, shoring and bracing as required to protect adjacent structures or improvements and to protect workmen and the public. The design of sheeting, shoring and bracing shall be the responsibility of the Contractor. The drawings shall be sealed by a Professional Engineer registered in the State of Texas.

2. Care shall be taken to prevent voids outside the sheeting. If voids are formed, they shall immediately be filled and compacted.

3. After completion of the structure, all sheeting, shoring and bracing shall be removed unless approval has been granted by the Engineer, in writing, to leave any or all of it in place. The sheeting, shoring and bracing shall be removed as excavations are backfilled in a manner that will prevent injurious caving of the excavation or damage to the structure.

4. Voids left or caused by removal of sheeting shall immediately be filled with suitable material and compacted.

B. Dewatering. Dewater excavations in such a manner that the foundation subgrade will be maintained in a satisfactory, undisturbed condition. Maintain the saturation line at least 2 feet below the lowest elevation where concrete is to be placed. The design of the dewatering system shall be the responsibility of the Contractor. The design of the dewatering system shall take into account any potential effect on any adjacent structures or facilities. Disposal of water shall conform to all applicable federal, state and local codes and ordinances.


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C. Pipe Trenches Under Structures. Excavate by open cut methods. Make and maintain the sides of the trench as nearly vertical as practical. Provide shoring as required to maintain the sides of the trench in a vertical position and to protect workmen. Shoring shall conform to the requirements of federal, state and local trench safety requirements. Complete and shape the trench to provide the minimum concrete backfill thickness shown on the drawings. Grade bottoms accurately to provide required slope.

D. Excavation.

1. Wherever practicable, cut all footing excavations to neat lines with a tolerance of minus 1 inch or plus 3 inches, and place concrete to bear against earth sides. Where beams are shown to be monolithic with slabs on ground, shape soil to the profile shown. Where grade beams are not monolithic with the slabs, the inside face of the grade beams shall be cast against neat-cut excavations. Excavate a sufficient distance from walls, shafts or similar elements of structures to allow for placing and removing forms and for inspections.

2. Excavate to the elevations shown on the drawings forming a level undisturbed surface free of mud or other soft material. Remove all pockets of soft or otherwise unstable soils and replace with concrete or with suitable well-compacted soil as directed by the Owner’s representative.

3. Fill all unauthorized excessive excavation with concrete at no change in the contract sum.

4. Protect all open excavations from rainfall or excessive drying so as to maintain the foundation subgrade in a satisfactory, undisturbed condition. Keep excavations reasonably free of water at all times and completely free of water during placement of concrete. Soils below foundation, which become soft, loose or otherwise unsatisfactory for support of the foundation as a result of inadequate excavation, dewatering or other construction methods, shall be removed and replaced with satisfactory material, as directed by the Owner’s representative, at the Contractor's expense.

5. In order to preserve the in situ moisture of the subgrade, do not remove the last 6-inch depth of excavation for slabs or footings until the seal slab is ready to be placed or where no seal slab is required until reinforcing steel and concrete are ready to be placed.

E. Drilled and Reamed Footings.

1. Notify Architect/Engineer before drilling footings.

2. The sequence of operations shall be so scheduled so that each underreamed excavation can be completed, reinforcing steel placed, and concrete poured in a continuous, rapid and orderly manner to minimize the time the excavation is open.

3. Some adjustments to footing depth may be required during construction if underreaming at design grade encounters excessive sloughing or caving, or footing bearing at the levels indicated is discovered to be insufficient. In either event, the Architect/Engineer may order the excavation carried to levels as necessary to obtain proper underreaming or bearing. Such additional work will be considered as additional work and performed on a unit cost basis in accordance with the contract documents.


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4. Execute drilled and underreamed type footings with approved type of equipment, manned by skilled personnel, which will provide required sizes, shapes and depths of footings and shafts. Provide a flat underream, free of loose earth and water prior to placing of concrete. Provide pumps at site for use to remove water in excavations.

5. Tolerance in Footing Alignment.

a. Vertical Misalignment. Less than 1 percent of depth.

b. Horizontal Misalignment. For 16-inch diameter shaft or less, 2 inches for 18-inch to 34-inch diameter shaft, 12 percent of shaft diameter; for 36-inch diameter shaft and larger, 4 inches.

6. In the event sloughing or caving is encountered in drilling the shafts, temporary casings shall be provided, sealing off such stratum. Such cost of temporary casings shall be considered as additional work and performed on a unit cost basis in accordance with the contract documents.

F. Spread Footing Building Foundation.

1. Individual footings may be constructed in open-cut excavations provided that minimum size of opening equals required size of footing indicated on structural drawings and that side slopes are not steeper than 1-vertical on 1.5-horizontal.

2. All loose soil at excavated grade shall be removed or re-compacted prior to pouring foundations.

3. Concrete shall be placed in foundation excavations the same day that excavation is completed to final grade. Base of excavations left open for longer periods shall be protected by a seal slab of lean concrete or cement-stabilized sand furnished and placed at Contractor’s expense.

3.4 BACKFILL

Complete backfill to the surface of natural ground or to the lines and grades shown on drawings. Use select material except where special materials are shown or specified. Deposit backfill in uniform layers and compact each layer as specified.

A. Backfill at Structures. Place backfill as promptly as practicable after completion of each structure or portion of a structure. Do not, however, place backfill against concrete walls or similar structures until concrete has been cured at least 7 days. Where the top of walls are supported by slabs or intermediate walls, do not begin backfill operations until the slab or intermediate walls have been placed and the concrete has cured for a minimum of 7 days. Remove concrete forms before starting backfill and remove shoring and bracing as the work progresses. Take care to prevent any wedging action of backfill against the structure. Step cut or serrate the slopes bounding the excavation as required to prevent wedging. Do not place expansive fill within 12 inches of structural wall. Do not compact fill against walls using heavy equipment which would surcharge the wall.

B. Backfill of Pipe Trenches Under Structures.

1. Do not backfill around pipe until the pipes have been inspected, tested and approved.

2. Use concrete backfill in pipe trenches which will be beneath concrete slabs or footings. Place initial concrete fill in equal layers along both sides of the pipe and carefully vibrate. Continue in this manner until the pipe is covered as detailed.

C. Compacting Backfill. Place material in uniform layers of prescribed maximum thickness and wet or dry the material to approximately optimum moisture content. Compact with power-driven hand tampers to the prescribed density.


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1. Regular Material. Place in 10-inch maximum layers, loose measure. Compact to a density equivalent to that of the adjacent undisturbed earth.

2. Select Material Against Structure. Place in 10-inch maximum layers, loose measure. Compact to a density equivalent to that of the adjacent undisturbed earth.

3. Select Material Under Structures. Place in 8-inch maximum layers, loose measure. Compact to not less than 98 percent of maximum soil density as determined by ASTM D 698.

4. Sand Material. Place in 6-inch maximum layers, loose measure. Compact to not less than 95 percent of maximum soil density as determined by ASTM D 4253 and D 4254.

5. Cement Stabilized Sand. Place in 8-inch maximum layers. Compact to a dry density of 115 pounds per cubic foot.

6. Compaction testing frequency shall be every 2,500 square feet per lift.

3.5 DISPOSAL OF EXCESS MATERIAL

Use excess excavation material or material unsuitable for backfill in site grading. Spread and grade as directed by the Owner’s representative. Dispose of excess or unsuitable material from the excavation off the job site in a legal manner.

END OF SECTION


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TRENCH SAFETY SYSTEMS 02320-1

SECTION 02320

TRENCH SAFETY SYSTEMS

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes the furnishing of a Trench Excavation and Shoring Safety Plan, including detailed plans and specifications for a trench safety system and requirements for a safety program for the trench system (including a plan for ingress and egress of the trenches, manholes and structures), to be incorporated into the bid documents and the Construction Contract, and all labor and materials for installation, inspection, and maintenance of trench safety system.

B. Application: For any trench excavation at a depth of 4 feet or greater, provide a trench safety system. Trench safety system is not required when (a) Contractor’s geotechnical engineer determines that the trench excavation is to be made in stable rock; or (b) excavations are less than four (4) feet in depth and examination of the ground by a competent person on behalf of the Contractor provides no indication that a cave-in should be expected. Trench safety system to be in accordance with Contractor’s Trench Excavation and Shoring Safety Plan, OSHA 2226, OSHA Technical Manual Section V Chapter 2, latest editions.

C. Modifications: All modifications to the Contractor’s Trench Excavation and Shoring Safety Plan or the detailed plans and specifications necessitated by the site conditions, Contractor’s trench construction means, methods, techniques or procedures and Contractor’s equipment to be used in construction of project facilities to be submitted to the Chief Engineer. All such modifications to be signed and sealed by a Registered Professional Engineer licensed in the State of Texas and a statement provided stating that the modified plan and/or the modified detailed plans and specifications for the trench safety system are designed in compliance with the Contractor’s Standard of Care and is in conformance with appropriate OSHA standards. Such modifications to Contractor’s plan and/or the Contractor’s detailed plans and specifications for the trench safety system to thereafter be incorporated into the Construction Contract.

1.2 RELATED WORK

A. Earthwork. Section 02223.


C. Excavation, Trenching and Backfilling for Utilities. Section 02315.

D. Structural Excavation, Fill, and Backfill. Section 02317.

E. Ductile Iron Pipe and Pipe Fittings. Section 15106.

1.3 PAYMENT

A. The design and installation of the trench safety system shall be measured and paid for by the linear foot of trench protected. Shoring of trench at manholes and other line structures shall be included in the linear foot cost.

B. There will be no increase in the Contract price resulting from the incorporation of the Contractor’s Trench Excavation and Shoring Safety Plan or Contractor’s detailed plans and specifications for the trench safety system into the proposed Contract Documents. There will be no increase in the Contract price resulting from modifications to the Contractor’s plan and/or the Contractor’s detailed plans and specifications for the trench safety system, whether or not the result of unforeseen or differing site or soil conditions.


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PART 2 - PRODUCTS

2.1 TIMBER

Trench sheeting materials shall be a minimum of 2 inches in thickness, solid and sound, free from weakening defects such as loose knots and splits. Shoring timber sizes shall not be less than that called for on the plans.

2.2 STEEL SHEET PILING

A. Steel sheet piling shall conform to ASTM A 36.

B. Steel for stringers and cross braces shall conform to ASTM A 36.

2.3 TRENCH BOXES

Portable trench boxes shall be constructed of steel conforming to ASTM A 36. Connecting bolts shall conform to ASTM A 307. Welds shall conform to requirements of AWS Specification D1.1.

PART 3 - EXECUTION

3.1 GENERAL

Trench safety systems shall be constructed, installed and maintained in accordance with the plans and/or to the design prepared by the Contractor's registered Professional Engineer licensed to practice in Texas to prevent death or injury to personnel or damage to structures in or near these trench excavations. Materials excavated from trench to be stored no closer to the edge of trench than one-half the depth of the trench.

3.2 INSTALLATION

A. Timber Sheeting. Timber sheeting to be installed in accordance with detail shown on plans. Drive timber sheeting to depth below trench bottom as shown on plans. Size of uprights, stringers and cross bracing to be in accordance with details shown on plans. Place cross braces in true horizontal position, spaced vertically, and secured to prevent sliding, falling or kickouts.

B. Steel Sheet Piling. Steel sheet piling of equal or greater strength may be substituted for timber trench shoring shown on the plans. Contractor to provide certification that steel sheet piling substituted provides equal or greater protection than timber trench shoring shown on plans. Certification of steel sheet piling to be provided by registered Professional Engineer. Drive steel sheet piling to minimum depth below trench bottom as recommended by Contractor's registered Professional Engineer licensed to practice in Texas providing design. Place cross braces in true horizontal position, spaced vertically and secured to prevent sliding, falling or kickouts.

C. Trench Boxes. Portable trench box to be substituted for timber trench shoring shown on plans shall be designed or the design checked by Contractor's registered Professional Engineer licensed to practice in Texas. Design trench box to provide equal or greater protection than timber trench shoring shown on plans. Certification of the design of trench boxes shall be provided by Contractor prior to its use on project. In cases where top of portable trench box will be below the top of trench, the trench must be sloped to an angle greater than the angle of repose for the soil conditions existing on the project. In areas where sloped trench will affect the integrity of existing structures, Contractor to protect structures prior to sloping trench.

D. Trench Jacks. When trench jacks are used for cross bracing and/or stringers, the Contractor shall provide certification by a registered Professional Engineer licensed to practice in Texas that the trench jacks provide protection greater than or equal to the timber cross bracing shown on plans.


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3.3 SUPERVISION

Contractor shall provide competent supervisory personnel at each trench while work is in progress to ensure Contractor's methods, procedures, equipment and materials pertaining to the safety systems in this item are sufficient to meet requirements of OSHA Standards.

3.4 MAINTENANCE OF SAFETY SYSTEM

The safety system shall be maintained in the condition as shown on plans or as specified by the Contractor's registered Professional Engineer licensed to practice in Texas. The Contractor shall take all necessary precaution to ensure the safety systems are not damaged during their use. If at any time during its use a safety system is damaged, personnel shall be immediately removed from the trench or excavation area and the safety system repaired. The Contractor shall take all necessary precautions to ensure no loads, except those included in the safety system design, are imposed upon the excavation.

3.5 INSPECTION

Contractor shall make daily inspection of trench safety systems to ensure that the systems meet OSHA requirements. Daily inspection to be made by competent personnel. If evidence of possible cave-ins or slides is apparent, all work in the trench shall cease until necessary precautions have been taken to safeguard personnel entering trench. Contractor shall maintain permanent record of daily inspections.

3.6 REMOVAL

Bed and backfill pipe to a point at least 1 foot above top of pipe prior to removal of any portion of trench safety systems. Bedding and backfill to be in accordance to other applicable specification items. Backfilling and removal of trench supports shall progress together from bottom of trench upward. Remove no braces or trench supports until all personnel have evacuated the trench. Backfill trench to within 4 feet of natural ground prior to removal of entire trench safety systems.

END OF SECTION


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CEMENT STABILIZED SAND 02321-1

SECTION 02321

CEMENT STABILIZED SAND

PART 1 - GENERAL


A. Cement stabilized sand.

1.2 REFERENCES

A. ASTM C 33 - Standard Specification for Concrete Aggregates (Fine Aggregate).

B. ASTM C 40 - Standard Test Method for Organic Impurities in Fine Aggregates for Concrete.

C. ASTM C 42 - Standard Test Methods for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete.

D. ASTM C 94 - Standard Specification for Ready-Mixed Concrete.

E. ASTM C 123 - Standard Test Method for Lightweight Particles in Aggregate.

F. ASTM C 142 - Standard Test Method for Clay Lumps and Friable Particles in Aggregates.

G. ASTM C 150 - Specification for Portland Cement.

H. ASTM D 558 - Standard Test Method for Moisture-Density Relations of Soil Cement- Mixtures.

I. ASTM D 1632 - Standard Practice for Making and Curing Soil-Cement Compression and Flexure Test Specimens in the Laboratory

J. ASTM D 1633 - Standard Test Method for Compressive Strength of Molded Soil-Cement Cylinders.

K. ASTM D 2487 - Standard Test Method for Classification of Soils for Engineering Purposes (Unified Soil Classification System).

L. ASTM D2922 - Standard Test Methods for Density of Soil and Soil-Aggregate in Place by Nuclear Methods (Shallow Depth)

M. ASTM D 3665 - Standard Practice for Random Sampling of Construction Materials.

N. ASTM D 4318 - Standard Test Method for Liquid Limit, Plastic Limit, and Plasticity Index of Soils.

1.3 SUBMITTALS


B. Submit proposed target cement content and production data for sand-cement mixture in accordance with requirements of Paragraph 2.03, Materials Qualifications.

1.4 DESIGN REQUIREMENTS

A. Use sand-cement mixture producing minimum unconfined compressive strength of 100 pounds per square inch (psi) in 48 hours.


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1. Design will be based on strength specimens molded in accordance with ASTM D 558 at moisture content within 3 percent of optimum and within 4 hours of batching.

2. Determine minimum cement content from production data and statistical history. Provide no less than 1.1 sacks of cement per ton of dry sand.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Cement: Type I Portland cement conforming to ASTM C 150.

B. Sand: Clean, durable sand meeting grading requirements for fine aggregates of ASTM C 33, or requirements for bank run sand of Section 02223 – Earthwork, and the following requirements:

1. Classified as SW, SP, SW-SM, SP-SM, or SM by Unified Soil Classification System of ASTM D 2487.

2. Deleterious materials:

a) Clay lumps, ASTM C 142 - less than 0.5 percent. b) Lightweight pieces, ASTM C 123; less than 5.0 percent. c) Organic impurities, ASTM C 40, color no darker than standard color.

3. Plasticity index of 4 or less when tested in accordance with ASTM D 4318.

C. Water: Potable water, free of oils, acids, alkalies, organic matter or other deleterious substances, meeting requirements of ASTM C 94.

2.2 MIXING MATERIALS

A. Add required amount of water and mix thoroughly in pugmill-type mixer.

B. Stamp batch ticket at plant with time of loading. Reject material not placed and compacted within 4 hours after mixing.

2.3 MATERIAL QUALIFICATION

A. Determine target cement content of material as follows:

1. Obtain samples of sand-cement mixtures at production facility representing range of cement content consisting of at least three points.

2. Complete molding of samples within 4 hours after addition of water.

3. Perform strength tests (average of two specimens) at 48 hours and 7 days.

4. Perform cement content tests on each sample.

5. Perform moisture content tests on each sample.

6. Plot average 48-hour strength vs. cement content.

7. Record scale calibration date, sample date, sample time, molding time, cement feed dial settings, and silo pressure (if applicable).

B. Test raw sand for following properties at point of entry into pug-mill:


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1. Gradation

2. Plasticity index

3. Organic impurities

4. Clay lumps and friable particles

5. Lightweight pieces

6. Moisture content

7. Classification

C. Present data obtained in format similar to that provided in sample data form attached to this Section.

D. The target content may be adjusted when statistical history so indicates. For determination of minimum product performance use formula:

f'c% 1/2 standard deviation

PART 3 - EXECUTION

3.1 PLACING

A. Place sand-cement mixture in maximum 12-inch-thick loose lifts and compact to 95 percent of maximum density as determined in accordance with ASTM D 558, unless otherwise specified. Refer to related specifications for thickness of lifts in other applications. Target moisture content during compaction is +3 percent of optimum. Perform and complete compaction of sand-cement mixture within 4 hours after addition of water to mix at plant.

B. Do not place or compact sand-cement mixture in standing or free water.

C. Where potable water lines cross wastewater line, embed wastewater line with cement stabilized sand in accordance with Texas Administrative Code §290.44(e)(4)(B):

1. Provide minimum of 10% cement per cubic yard of cement stabilized sand mixture, based on loose dry weight volume. Use at least 2.5 bags of cement per cubic yard of mixture (2 sacks per ton of dry sand).

2. Unless otherwise shown on Drawings, embed wastewater main or lateral minimum of six inches above and below.

3. Use brown coloring in cement stabilized sand for wastewater main or lateral bedding for identification of pressure rated wastewater mains during future construction.

3.2 FIELD QUALITY CONTROL

A. Testing will be performed under provisions of Section 01380 – Quality Control.


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B. One sample of cement stabilized sand shall be obtained for each 150 tons of material placed per day with no less than one sample per day of production. Random samples of delivered cement stabilized sand shall be taken in the field at point of delivery in accordance with ASTM 3665. Obtain three individual samples of approximately 12 to 15 lb each from the first, middle, and last third of the truck and composite them into one sample for test purpose.

C. Prepare and mold four specimens (for each sample obtained) in accordance with ASTM D 558, Method A, without adjusting moisture content. Samples will be molded at approximately same time material is being used, but no later than 4 hours after water is added to mix.

D. After molding, specimens will be removed from molds and cured in accordance with ASTM D 1632.

E. Specimens will be tested for compressive strength in accordance with ASTM D 1633, Method A. Two specimens will be tested at 48 hours plus or minus 2 hours and two specimens will be tested at 7 days plus or minus 4 hours.

F. A strength test will be average of strengths of two specimens molded from same sample of material and tested at same age. Average daily strength will be average of strengths of all specimens molded during one day's production and tested at same age.

G. Precision and Bias: Test results shall meet recommended guideline for precision in ASTM D 1633 Section 9.

H. Reporting: Test reports shall contain, as a minimum, the following information:

1. Supplier and plant number

2. Time material was batched

3. Time material was sampled

4. Test age (exact hours)

5. Average 48-hour strength

6. Average 7-day strength

7. Specification section number

8. Indication of compliance / non-compliance

9. Mixture identification

10. Truck and ticket numbers

11. The time of molding

12. Moisture content at time of molding

13. Required strength

14. Test method designations

15. Compressive strength data as required by ASTM D 1633

16. Supplier mixture identification


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17. Specimen diameter and height, in.

18. Specimen cross-sectional area, sq. in.

3.3 ACCEPTANCE

A. Strength level of material will be considered satisfactory if:

1. The average 48-hour strength is greater than 100 psi with no individual strength test below 70 psi.

2. All 7-day individual strength tests (average of two specimens) are greater than or equal to 100 psi.

B. Material will be considered deficient when 7-day individual strength test (average of two specimens) is less than 100 psi but greater than 70 psi. See Paragraph 3.04 Adjustment for Deficient Strength.

C. The material will be considered unacceptable and subject to removal and replacement at

Contractor=s expense when individual strength test (average of two specimens) has 7-

day strength less than 70 psi.

D. When moving average of three daily 48-hour averages falls below 100 psi, discontinue shipment to project until plant is capable of producing material, which exceeds 100 psi at 48 hours. Five 48-hour strength tests shall be made in this determination with no individual strength tests less than 100 psi.

E. Testing laboratory shall notify Contractor, Owner’s Representative, and material supplier by facsimile of tests indicating results falling below specified strength requirements within 24 hours.

F. If any strength test of laboratory cured specimens falls below the specified strength, Contractor may, at his own expense, request test of cores drilled from the area in question in accordance with ASTM C42. In such cases, three (3) cores shall be taken for each strength test that falls below the values given in 3.03.A.

G. Cement stabilized sand in an area represented by core tests shall be considered satisfactory if the average of three (3) cores is equal to at least 100 psi and if no single core is less that 70 psi. Additional testing of cores extracted from locations represented by erratic core strength results will be permitted.

3.4 ADJUSTMENT FOR DEFICIENT STRENGTH

A. When mixture produces 7-day compressive strength greater than or equal to 100 psi, then material will be considered satisfactory and bid price will be paid in full.

B. When mixture produces 7-day compressive strength less than 100 psi and greater than or equal to 70 psi, material shall be accepted contingent on credit in payment. Compute credit by the following formula:

Credit per Cubic Yard = $30.00 x 2 (100 psi - Actual psi) 100


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C. When mixture produces 7-day compressive strength less than 70 pounds per square inch, then remove and replace cement-sand mixture and paving and other necessary work at no cost to Owner.

END OF SECTION


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FLOWABLE FILL 02322-1

SECTION 02322

FLOWABLE FILL

PART 1 - GENERAL


A. Flowable Fill for furnishing, mixing, transporting and placing flowable fill.

1.2 REFERENCES

A. ASTM C 31 – Making and Curing Concrete Test Specimens in the field.

B. ASTM C 39 – Compressive Strength of Cylindrical Concrete Specimens.

C. ASTM C 40 – Organic Impurities in Fine Aggregates for Concrete.

D. ASTM C 94 - Ready-Mixed Concrete.

E. ASTM C 150 - Portland Cement.

F. ASTM C 192 – Making and Curing Concrete Test Specimens in the Laboratory.

G. ASTM C 260 – Air-Entraining Admixtures for Concrete.

H. ASTM C 494 - Chemical Admixtures for Concrete.

I. ASTM C 618 – Coal Fly Ash and Raw or Calcined Natural Pozzolan for use as a Mineral Admixture in Concrete.

J. ASTM C 4318 – Liquid Limit, Plastic Limit and Plasticity Index of Soils.

1.3 SUBMITTALS


B. Submit proposed mix design

C. Submit a copy of delivery tickets accompanied by batch tickets, providing the information required by ASTM C 94 to Engineer in the field at time of delivery.

PART 2 - PRODUCTS

2.1 GENERAL

A. Provide material conforming to:

1. Cement- ASTM C 150, Type I.

2. Fly Ash – ASTM C 618, Class C, with a minimum CaO content of 20 percent.

3. Water- ASTM C 94.


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4. Fine Aggregate – Natural or manufactured fine aggregate, or a combination there of, free from deleterious amounts of salt, alkali, vegetable matter or other objectionable material. The plasticity index shall be 4 or less when tested in accordance with ASTM D 4318. Organic impurities, when tested in accordance with ASTM C 40, shall not show a color darker then the standard color. It is intended that the fine aggregate be fine enough to stay in suspension in the mortar to the extent required for proper flow. The fine aggregate shall conform to the following gradation:

Sieve Size Percent Passing

3/8 inch 100 No. 200 0-10

If flowable mixture cannot be produced, the fine aggregate may not be approved.

5. Admixtures – ASTM C 260 and /or C 494.

2.2 MIX DESIGN

A. A. Mix design shall state the following information:

1. Mix design number or code designation to order the concrete from the supplier.

2. Design strength at 7 days (unless otherwise noted on the Plans).

3. Cement type and brand.

4. Fly ash type and brand.

5. Admixtures type and brand.

6. Proportions of each material used.

B. Minimum strength requirement is 100 psi in 7 days unless otherwise noted on the Plans.

PART 3 - EXECUTION

3.1 BATCHING, MIXING AND TRANSPORTATION

A. Batch, mix and transport flowable fill in accordance with ASTM C 94, except when directed otherwise by the Engineer.

B. Mix flowable fill in quantities required for immediate use. Do not use portions which have developed initial set or which are not in place within 90 minutes after the initial water has been added.

C. Do not mix flowable fill while the air temperature is at or below 35 degrees F. without prior approval of the Engineer.


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3.2 PLACEMENT

A. Seal off the area to be repaired.

B. Monitor and control the fluid pressure during placement of flowable fill prior to set. Take appropriate measures to avoid excessive pressure that may damage or displace structures or cause flotation. Cease operations if flowable fill is observed leaking from the repair area. Repair or replace damaged or displaced structures at no additional cost.

3.3 TESTING AND INSPECTION

A. Refer to Section 01457 – Construction Tests and Inspection.

3.4 CLEAN UP

A. Clean up excess flowable fill discharged from the work area and remove excess flowable fill from pipes at no additional cost.

B. Refer to Section 02120 – Material Disposal.

END OF SECTION


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LIME-STABILIZED SUBGRADE 02336-1

SECTION 02336

LIME-STABILIZED SUBGRADE

PART 1 - GENERAL


A. Foundation course of lime stabilized subgrade material.

1. Application of lime slurry to subgrade.

2. Mixing, compaction, and curing of lime slurry, water, and subgrade into a stabilized foundation.

1.2 DEFINITION

A. Moist Cure: Curing soil and lime to obtain optimum hydration.

B. 1000-Foot Roadway Section: 1000 feet per lane width or approximately 500 square yards of compacted subgrade for other than full-lane-width roadway sections.

1.3 REFERENCES

A. ASTM D 698 - Standard Test Method for Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 ft-lbf/ft3 (600 kN-m/m3).

B. ASTM D 2922 - Standard Test Methods for Density of Soil and Soil-Aggregate in Place by Nuclear Methods (Shallow Depth).

C. ASTM D 4318 - Standard Test Method for Liquid Limit, Plastic Limit, and Plasticity Index of Soils.

D. TxDOT Tex-101-E (Part III) - Preparation of Soil and Flexible Base Material for Testing.

E. TxDOT Tex-140-E - Measuring Thickness of Pavement Layer.

F. TxDOT Tex-600-J - Sampling and Testing Hydrated Lime, Quicklime, and Commercial Lime Slurry.

1.4 SUBMITTALS


B. Submit certification that hydrated lime, quicklime, or commercial lime slurry complies with specifications.

C. Submit weight tickets, certified by supplier, with each bulk delivery of lime to work site.

1.5 DELIVERY, STORAGE AND HANDLING

A. Bagged lime shall bear manufacturer's name, product identification, and certified weight. Bags varying more than 5 percent of certified weight may be rejected; average weight of 50 random bags in each shipment shall not be less than certified weight.

B. Store lime in weatherproof enclosures. Protect lime from ground dampness.

PART 2 - PRODUCTS

2.1 WATER

A. A. Use clean, clear water, free from oil, acids, alkali, or vegetation.


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2.2 LIME

A. Type A - Hydrated Lime: Dry material consisting essentially of calcium hydroxide or mixture of calcium hydroxide and an allowable percentage of calcium oxide as listed in chemical composition chart.

B. Type B - Commercial Lime Slurry: Liquid mixture consisting essentially of lime solids and water in slurry form. Water or liquid portion shall not contain dissolved material in sufficient quantity to be injurious or objectionable for purpose intended.

C. Type C - Quicklime: Dry material consisting essentially of calcium oxide. Furnish quicklime in either of the following grades:

1. Grade DS: Pebble quicklime of gradation suitable for use in preparation of slurry for wet placing.

2. Grade S: Finely-graded quicklime for use in preparation of slurry for wet placing. Donor use grade S quicklime for dry placing.

D. Conform to the following requirements:

CHEMICAL COMPOSITION TYPE

A B C

Active lime content, % by weight Ca(OH)2+CaO 90.0 min1

Unhydrated lime content, % by weight CaO 5.0 max

Free water content, % by weight H2O: 5.0 max

SIZING

Wet Sieve, as % by weight residue retained:

No. 6 0.2 max 0.2 max2 8.0 max3

No. 30 4.0 max 4.0 max2 -

Dry sieve, as % by weight residue retained:

1-inch - - 0.0

1/2-inch - - 10.0 max

Notes: 1. Maximum 5.0% by weight CaO shall be allowed in determining total active lime content. 2. Maximum solids content of slurry. 3. Total active lime content, as CaO, in material retained on No. 6 sieve shall not exceed

2.0% by weight of original Type C lime.


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E. Deliver lime slurry to job site as commercial lime, or prepare at job site by using hydrated lime or quicklime. Provide slurry free of liquids other than water and of consistency that can be handled and uniformly applied without difficulty.

F. Lime containing magnesium hydroxide is prohibited.

2.3 SOIL

A. Soil to receive lime treatment may include borrow or existing subgrade material, existing pavement structure, or combination of all three. Where existing pavement or base material is encountered, pulverized or scarify material so that 100 percent of sampled material passes 2- inch sieve.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Verify compacted subgrade will support imposed loads.

B. Verify subgrade lines and grades.

3.2 PREPARATION

A. A. Complete backfill of utilities prior to stabilization.

B. B. Cut material to bottom of subgrade using an approved cutting and pulverizing machine meeting following requirements:

1. Cutters accurately provide smooth surface over entire width of cut to plane of secondary grade.

2. Provide cut to depth as specified or shown in the Drawings.

C. Alternatively, scarify or excavate to bottom of stabilized subgrade. Remove material or windrow to expose secondary grade. Obtain uniform stability.

D. Correct wet or unstable material below secondary grade by scarifying, adding lime, and compacting as directed by Owner’s Representative.

E. Pulverize existing material so that 100 percent passes a 1-3/4-inch sieve.

3.3 LIME SLURRY APPLICATION

A. Apply slurry with distributor truck equipped with an agitator to keep lime and water in consistent mixture. Make successive passes over measured section of roadway to attain proper moisture and lime content. Limit spreading to an area where preliminary mixing operations can be completed on same working day.

B. Minimum lime content shall be 5 percent of dry unit weight of subgrade as determined by ASTM D 698

3.4 PRELIMINARY MIXING

A. Use approved single-pass or multiple-pass rotary speed mixers to mix soil, lime, and water to required depth. Obtain homogeneous friable mixture free of clods and lumps.

B. Shape mixed subgrade to final lines and grades.

C. Eliminate following operations and final mixing if pulverization requirements of Paragraph 3.05C can be met during preliminary mixing:


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1. Seal subgrade as precaution against heavy rainfall by rolling lightly with light pneumatic rollers.

2. Cure soil lime material for 24 to 72 hours or as required to obtain optimum hydration. Keep subgrade moist during cure.

3.5 FINAL MIXING

A. Use approved single-pass or multiple-pass rotary speed mixers to uniformly mix cured soil and lime to required depth.

B. Add water to bring moisture content of soil mixture to optimum or above.

C. Mix and pulverize until all material passes 13/4-inch sieve; minimum of 85 percent, excluding non-slacking fractions, passes 3/4-inch sieve; and minimum of 60 percent excluding non-slacking fractions passes No. 4 sieve. Test according to TxDOT Tex-101-E, Part III using dry method.

D. Shape mixed subgrade to final lines and grades.

E. Do not expose hydrated lime to open air for 6 hours or more during interval between application and mixing. Avoid excessive hydrated lime loss due to washing or blowing.

3.6 COMPACTION

A. Aerate or sprinkle to attain optimum moisture content to 3 percent above optimum, as determined by ASTM D 698 on material sample from roadway after final mix with lime.

B. Start compaction immediately after final mixing.

C. Spread and compact in two or more equal layers where total compacted thickness is greater than equipment manufacturer’s recommended range of mixing and compaction.

D. Compact with approved heavy pneumatic or vibrating rollers, or combination of tamping rollers and light pneumatic rollers. Begin compaction at bottom and continue until entire depth is uniformly compacted.

E. Do not allow stabilized subgrade to mix with underlying material. Correct irregularities or weak spots immediately by replacing material and recompacting.

F. Compact subgrade to minimum density of 95 percent of maximum dry density, according to ASTM D 698, at moisture content of optimum to 3 percent above optimum, unless otherwise indicated on Drawings:

G. Seal with approved light pneumatic tired rollers. Prevent surface hair line cracking. Rework and recompact at areas where hairline cracking develops.

3.7 CURING

A. Moist cure for minimum of 3 days before placing base or surface course, or opening to traffic. Subgrade may be opened to traffic after 2 days when adequate strength has been attained to prevent damage. Restrict traffic to light pneumatic rollers or vehicles weighing less than 10 tons.

B. Keep subgrade surface damp by sprinkling. Roll with light pneumatic roller to keep surface knit together.


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C. Place base or surface within 14 days after final mixing and compaction. Restart compaction and moisture content of base material when time is exceeded.

3.8 TOLERANCES

A. Completed surface: smooth and conforming to typical section and established lines and grades.

B. Top of compacted surface: Plus or minus 1/4 inch in cross section or in 16-foot length.

C. Depth of lime stabilization shall be plus or minus one inch of specified depth for each 1000- foot roadway section.



B. Test soils, lime, and mixtures as follows:

1. Tests and analysis of soil materials will be performed in accordance with ASTM D 4318, using the wet preparation method.

2. Sampling and testing of lime slurry shall be in accordance with TxDOT Tex-600-J, except using a lime slurry cup.

3. Sample mixtures of hydrated lime or quicklime in slurry form will be tested to establish compliance with specifications.

4. Moisture-density relationship will be established on material sampled from roadway, after stabilization with lime and final mixing, in accordance with ASTM 698, Moist preparation Method.

C. In-place depth will be evaluated for each 1000-foot roadway section and determined in accordance with TxDOT Tex-140-E in hand excavated holes. For each 1000-foot section, 3 phenolphthalein tests will be performed. Average stabilization depth for 1000-foot section will be based on average depth for three tests.

D. Perform compaction testing in accordance with ASTM D 2922. Three tests will be performed for each 1000-foot roadway section.

E. Pulverization analysis will be performed as required by Paragraph 3.05C on material sampled during mixing of each production area. Three tests will be performed per 1000-foot roadway section or a minimum of once daily.

3.10 REWORK OF FAILED SECTIONS

A. Rework sections that do not meet specified thickness.

B. Perform the following steps when more than 72 hours have lapsed since completion of compaction.

1. Moist cure for minimum of 3 days after compaction to required density.

2. Add lime at rate of 25 percent of specified rate at no additional cost to Owner.

3. Moisture density test of reworked material must be completed by laboratory before field compaction testing can be completed.


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3.11 PROTECTION

A. Maintain stabilized subgrade to lines and grades and in good condition until placement of base or surface course. Protect asphalt membrane from being picked up by traffic.

B. Repair defects immediately by replacing material to full depth.

END OF SECTION


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LIME/FLY ASHSTABILIZED SUBGRADE 02337-1

SECTION 02337

LIME/FLY ASH STABILIZED SUBGRADE

PART 1 - GENERAL


A. Foundation course of lime/fly ash stabilized subgrade material.

1. Application of lime slurry and fly ash to subgrade

2. Mixing, compaction, and curing of lime, slurry, fly ash, water and subgrade into a stabilized foundation

1.2 DEFINITIONS

A. Moist Cure: Curing soil lime/fly ash material to obtain optimum hydration.

B. 1000-Foot Roadway Section: 1000 feet per lane width or approximately 500 square yards of compacted subgrade for other than full-lane-width roadway sections.

1.3 REFERENCES

A. ASTM C 618 - Standard Specification for Coal Fly Ash and Raw or Calcinated Natural Pozzolan for use as Mineral Admixture in Portland Cement Concrete.

1.4 SUBMITTALS


B. Submit certification that fly ash, hydrated lime, quicklime, or commercial lime slurry complies with these specifications.

C. Submit weight tickets, certified by supplier, with each bulk delivery of materials to work site.

1.5 DELIVERY, STORAGE, AND HANDLING

A. Conform to requirements of Section 02336 - Lime Stabilized Subgrade.

B. Quicklime can be dangerous; exercise extreme caution if used for Work. Become informed about recommended precautions in handling, storage and use of quicklime.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Water: clean, clear and free from oil, acids, alkali, or vegetable matter.

B. Conform to requirements of Section 02336 - Lime Stabilized Subgrade for Type A hydrated lime, Type C quicklime, and Type B commercial lime slurry.

C. Fly ash: Residue or ash remaining after burning finely pulverized coal at high temperatures conforming to requirements of ASTM C 618, Type ‘C” or “F” and following:

1. Minimum CaO content of 20 percent

2. Loss on ignition not to exceed 3 percent


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LIME/FLY ASHSTABILIZED SUBGRADE 02337-2

3. Contain no lignite ash

D. Asphaltic Seal Cure: Conform to requirements of Section 02336 - Lime Stabilized Subgrade.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Conform to Part 3 of Section 02336 - Lime Stabilized Subgrade with following exceptions:

1. Include fly ash in percentage amounts in lime or lime slurry as established from geotechnical evaluation for application, mixing, and compaction.

2. Apply lime/fly ash as single mix, single pass over lower PI soils.

3. Conduct operations to minimize elapsed time between mixing and compacting lime/fly ash stabilized subgrade in order to take advantage of rapid initial set characteristics. Complete compaction within 2 hours of commencing compaction and not more than 6 hours after adding and mixing last stabilizing agent.

3.2 QUALITY CONTROL


B. Soil will be sampled to establish percent of fly ash and hydrated lime, quicklime, or lime slurry to be applied to subgrade material.

C. Testing will be in accordance with Part 3 of Section 2336-Lime-Stabilized Subgrade.

END OF SECTION


WATER PLANTS

GEOTEXTILE 02370-1

SECTION 02370

GEOTEXTILE

PART 1 - GENERAL


A. Geotextile, also called filter fabric, in applications such as under a granular fill, as a pipe embedment wrap, around the exterior of a tunnel liner, or around the foundations of pipeline structures.

B. References to Technical Specifications:

1. Section 01330 – Submittal Procedures.

C. Referenced Standards:

1. American Society for Testing and Materials (ASTM)

a) ASTM D 4632, Standard Test Method for Grab Breaking Load and Elongation of Geotextiles”

b) ASTM D 4533, “Standard Test Method for Trapezoid Tearing Strength of Geotextiles”

c) ASTM D 4833, “Standard Test Method for Index Puncture Resistance of Geotextiles, Geomembranes, and Related Products”

d) ASTM D 3786, “Standard Test Method for Hydraulic Bursting strength of Textile Fabrics”

e) ASTM D 4751, “Standard Test Method for Determining Apparent Opening Size of a Geotextile”

f) ASTM D 4491, “Standard Test Method for Water Permeability of Geotextiles by Permittivity”

2. American Association of State Highway and Transportation Officials

(AASHTO)

1.2 SUBMITTALS

A. Make Submittals required by this Section under the provisions of Section 01330 – Submittal Procedures.

B. Submit the standard manufacturer's catalog sheets and other pertinent information, for approval, prior to installation.

C. Submit installation methods, as a part of the work plan for tunneling or for excavation and backfill for utilities. Obtain approval from Engineer for Geotextile material and the proposed installation method prior to use of the geotextile.

D.

PART 2 - PRODUCTS

2.1 GEOTEXTILE

A. Provide a geotextile (filter fabric) designed for use in geotechnical applications which forms a permeable layer or media while retaining the soil matrix.


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GEOTEXTILE 02370-2

B. Use a fabric which meets the physical requirements for Class A Subsurface Drainage installation conditions as defined in AASHTO M288 and as specified in this Section, 2.02 “Properties”.

2.2 PROPERTIES

A. Material: Non-woven, non-biodegradable, fabric consisting only of continuous chain polymer filaments or yarns, at least 85 percent by weight poly-olefins, polyesters or polyamide, formed into a dimensionally stable network.

B. Chemical Resistance: Inert to commonly encountered chemicals and hydrocarbons over a pH range of 3 to 12.

C. Physical Resistance: Resistant to mildew and rot, ultraviolet light exposure, insects and rodents.

D. Minimum Test Values:

PROPERTY VALUE (MIN) TEST METHOD

Grab strength 180 lbs ASTM D 4632

Trapezoidal Tear Strength 50 lbs ASTM D 4533

Puncture Strength 80 lbs ASTM D 4833

Mullen Burst Strength 290 psi ASTM D 3786

Apparent Opening Size (1) 0.25 mm ASTM D 4751

Permittivity (sec-1) 0.2 ASTM D 4491

(1) Maximum average roll value

PART 3 - EXECUTION – Not used

END OF SECTION


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CUT, PLUG, AND ABANDONMENT OF WATER LINES 02516-1

SECTION 02516

CUT, PLUG, AND ABANDONMENT OF WATER LINES

PART 1 - GENERAL


A. Cut, plug and abandonment of water lines.

1.2 SUBMITTALS


B. Submit product data for proposed plugs and clamps for approval.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Concrete for reaction blocks: Class B conforming to requirements of Section 03310 – Cast-in-Place Concrete.

B. Plugs and clamps: Applicable for type of pipe to be plugged.

PART 3 - EXECUTION

3.1 APPLICATION

A. Do not begin cut, plug and abandonment operations until replacement water line has been constructed, disinfected, and tested, and service lines have been transferred to replacement water line.

B. Install plug, clamp, and concrete reaction block and make cut at location shown on Drawings.

C. Main to be abandoned shall not be valved off and shall not be cut or plugged other than at supply water line or as shown on Drawings.

D. After water line to be abandoned has been cut and plugged, check for other sources feeding abandoned water line. When sources are found, notify Owner’s Representative immediately. Cut and plug abandoned water line at point of other feed as directed by Owner’s Representative.

E. Plug or cap ends or openings in abandoned water line in manner approved by Owner’s Representative.

F. Remove and dispose of surface identifications such as valve boxes and fire hydrants. Valve boxes in improved streets, other than shell, may be filled with concrete after removing cap.

G. Backfill excavations in accordance with Section 02315 – Excavation, Trenching, and Backfill for Utilities.

H. Repair street surfaces in accordance with Drawings.

END OF SECTION


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CUT, PLUG, AND ABANDONMENT OF WATER LINES 02516-2

BLANK PAGE


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POLYETHYLENE ENCASEMENT / WRAP 02528-1

SECTION 02528

POLYETHYLENE ENCASEMENT / WRAP

PART 1 - GENERAL


A. Polyethylene encasement that may be part of the corrosion protection system for pipe, valves, fittings, and other appurtenances in ductile or cast iron systems.

1.2 REFERENCES

A. ASTM D 149 – Standard Test Method for Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulating Materials at Commercial Power Frequencies.

B. B. ASTM D 882 – Standard Test Method for Tensile Properties of Thin Plastic Sheeting.

C. ASTM D 1709 – Standard Test Methods for Impact Resistance of Plastic Film by the Free- Falling Dart Method.

D. ASTM D 1922 – Standard Test Method for Propagation Tear Resistance of Plastic Film and Thin Sheeting by Pendulum Method.

E. ASTM D 4976 – Standard Specification for Polyethylene Plastics Molding and Extrusion Materials.

F. ANSI/AWWA C600 – Standard for Installation of Ductile-Iron Water Mains and Their Appurtenances.

G. ANSI/AWWA C105/A21.5 - Polyethylene Encasement for Ductile-Iron Piping for Water and Other Liquids.

1.3 SUBMITTALS

A. Submittal Procedures: Submit product data in accordance with Section 01330 – Submittal Procedures.

B. Product Data: Submit product data for proposed film, and tape or plastic tie straps for approval. All film to be used in accordance with this standard specification will be manufactured from virgin polyethylene, will not be recycled and shall be purchased new for the project, clean, sound and without defects.

C. Samples: Submit samples of polyethylene tube and/or sheet for approval. Provide one sample of tube for each pipe diameter and one sample of each sheet material to be used. Samples will be a minimum of 40 square feet of standard production material.

D. Quality Assurance Plan: Submit quality assurance plans for film manufacturing and field application.

1. Film Manufacturing: The manufacturer of polyethylene film for corrosion protection encasement of ductile iron pipe will have a verifiable quality control system to assure that film is produced from only virgin polyethylene and that it complies with all requirements of this specification. Documentation of Quality Control procedures and test results will be submitted and will be made available for inspection for at least one year subsequent to delivery to job site.

2.


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3. Field Application: The contractor will develop, and submit for approval, a comprehensive Quality Assurance Plan for installation of polyethylene encasement. Address all aspects of material and pipe handling, bedding, preparation of pipe surface, film installation and anchoring, service taps and backfill. Include written procedures to be used by installers.

E. Manufacturer’s Certification: Submit polyethylene film manufacturer's certification of compliance with this Section. The polyethylene film manufacturer will provide a notarized statement from an officer of the company that the film meets the inspection and all applicable material specifications of this specification. The manufacturer’s statement of compliance must be verifiable. Statements from distributors or contractors will not be accepted in lieu of a statement from the original manufacturer of the polyethylene film.

F. Installer Qualifications: Polyethylene encasement will only be installed by qualified persons who have been trained in the proper procedures described in Part 3 of these specifications. Qualified Persons: Qualified persons shall be those that have had training and experience in the installation of polyethylene encasement for corrosion protection of ductile iron pipe. Such persons may be qualified by the Ductile Iron Pipe Research Association, ductile iron pipe manufacturers or engineering/inspection firms who offer training courses in the proper.

G. Method(s) of installation. Proof of qualifications shall be submitted with the shop drawings and shall be provided to project inspectors upon request.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Polyethylene Film: Tubular or sheet form without tears, breaks or defects, conforming to the following requirements.

1. High-Density, Cross-Laminated, Polyethylene: High–density, cross-laminated polyethylene film manufactured from virgin polyethylene material conforming to the following:

a) Raw Material. Raw materials to meet the requirements of ASTM D 4976: i. Group: 2 (Linear) ii. High-density: 0.940 to 0.960 g/cm3 iii. Volume resistivity: 1015 ohm-cm, minimum

b) Physical Properties. Physical properties of finished film to be as follows: i. Tensile Strength: 6,300 psi, minimum in machine and transverse

direction (ASTM D 882). ii. Elongation: 100 percent, minimum in machine and transverse

direction (ASTM D 882) as measured using rubber lined grips. iii. Dielectric Strength: 800 volts/mil thickness, minimum (ASTM D 149) iv. Impact Resistance: 800 grams, minimum (ASTM D 1709 Method B) v. Propagation Tear Resistance: 250 grams force, minimum in machine

and transverse direction (ASTM D1922) c) Thickness: High-density, cross-laminated polyethylene film shall have a

nominal thickness of 0.004 in. (4 mils) with a minus 10% tolerance. Nowhere shall the film be less than 0.0036 (3.6 mils).

d) Color: Supply white polyethylene film with a minimum 2 percent hindered-amine ultraviolet inhibitor.

e) Polyethylene Tube and Sheet Size: For push-on joint pipe, polyethylene tube and sheet sizes to conform to the following:


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Nominal Diamter

Pipe Minimum Polyethylene

Width - Inches

Inches Flat Tube Sheet

3 14 28

4 14 28

6 16 32

8 20 40

10 24 48

12 27 54

14 30 60

16 34 68

18 37 74

20 41 82

24 54 108

30 67 134

36 81 162

42 81 162

48 95 190

54 108 216

60 108 216

64 121 242

2. Large Bell Circumferences: Where bell ends of the pipe are larger than the sheet sizes listed above, use sufficiently large tubes or sheets to cover the joints

3. Marking: The polyethylene film will be clearly marked every two feet with the following information:

a) Manufacturer's name or trademark b) Year of manufacture c) ANSI/AWWA C105/A21.5


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d) Minimum film thickness and material type (HDCLPE) e) Applicable range of nominal pipe diameter size(s) f) Warning – Corrosion Protection – Repair Any Damage Letters and numerals

used for marking items "a" through "e" shall not be less than 1 inch in height and item "f" shall not be less than 1 1/2 inches in height.

B. Plastic Tape: Provide 1 ½-inch wide, 6 mil thick, PVC tape with 5 mils of PVC backing and 1 mil of rubber adhesive for fitting, anchoring and repairing the encasement.

PART 3 - EXECUTION

3.1 PREPARATION

A. Remove lumps of clay, mud, and cinders from pipe surface prior to installation of polyethylene encasement. Prevent soil or embedment material from becoming trapped between pipe and polyethylene.

B. Fit polyethylene film to contour of pipe to effect a snug, but not tight fit; encase with minimum space between polyethylene and pipe. Allow sufficient slack in contouring to prevent stretching polyethylene where it bridges irregular surfaces, such as bell-spigot interfaces, bolted joints, or fittings, and to prevent damage to polyethylene due to backfilling operations. Secure overlaps and ends with adhesive tape to hold polyethylene encasement in place until backfilling operations are complete.

C. For installations below water table or in areas subject to tidal actions, seal both ends of polyethylene tube with adhesive tape at joint overlap. Circumferentially wrap with tape, every two feet along the barrel.

3.2 INSTALLATION

A. A. Tubular Type (Method A):

1. Cut polyethylene tube to a length approximately 2 feet longer than pipe section. Slip tube around pipe, centering tube to provide 1-foot overlap on each adjacent pipe section. Bunch accordion-fashion lengthwise until it clears pipe ends.

2. Make shallow bell hole at joints to facilitate installation of polyethylene tube completely around pipe. Lower pipe into trench and make up pipe joint with preceding section of pipe. Methods other than bell holes shall be allowed, provided the polyethylene tube completely encases the pipe joints, including a minimum overlap of 1-foot.

3. After assembling pipe joint, make overlap of polyethylene tube. Pull bunched polyethylene from preceding length of pipe, slip it over end of adjoining length of pipe, and secure in place. Then slip end of polyethylene from adjoining pipe section over end of first wrap until it overlaps joint at end of preceding length of pipe. Secure overlap in place.

4. For each pipe length, take up slack width at top of pipe to make a snug, but not tight, fit along barrel of pipe, securing fold with tape at quarter points. Avoid a tight fit to prevent stretching the polyethylene where it bridges irregular surfaces, such as bell and spigot joints, restrained and bolted joints, and fittings; and to prevent damage to film during backfilling. The length of tape to secure wrap shall be no less than 1-foot.


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5. Repair cuts, tears, punctures, or other damage to polyethylene. Proceed with installation of next section of pipe in same manner.

B. Tubular Type (Method B):

1. Cut polyethylene tube to a length approximately 1 foot shorter than pipe section. Slip tube around pipe, centering it to provide 6 inches of bare pipe at each end.

2. Make shallow bell hole at joints to facilitate installation of polyethylene tube completely around pipe. Lower pipe into trench and make up pipe joint with preceding section of pipe. Methods other than bell holes shall be allowed, provided the polyethylene tube completely encases the pipe joints, including a minimum overlap of 1-foot.

3. Take up slack width at top of pipe to make a snug, but not tight, fit along barrel of pipe, securing fold with tape at quarter points. Avoid a tight fit to prevent stretching the polyethylene where it bridges irregular surfaces, such as bell and spigot joints, restrained and bolted joints, and fittings; and to prevent damage to film during backfilling. The length of tape to secure wrap shall be no less than 1-foot.

4. Before making up joint, slip 4-foot length of polyethylene tube over end of preceding pipe section, bunching in accordion-fashion lengthwise. After completing joint, pull 4- foot length of polyethylene over joint, overlapping polyethylene previously placed on each adjacent section of pipe by at least 1 foot; make each end snug and secure.


C. Sheet Type (Method C) – Applicable to Valves, Tees, Elbows and Other Fittings Only:

1. Cut polyethylene sheet to a length approximately 2 feet longer than pipe section. Center length to provide 1-foot overlap on each adjacent pipe section, bunching sheet until it clears pipe ends. Wrap polyethylene around pipe so that sheet circumferentially overlaps top quadrant of pipe. Secure cut edge of polyethylene sheet at intervals of approximately 3 feet.

2. Lower wrapped pipe into trench and make up pipe joint with preceding section of pipe. Make shallow bell hole at joints to facilitate installation of polyethylene. After completing joint, make overlap and secure ends.


D. Installation in Augured Hole or Directional Drilled Bore:

E. Install as described in 3.02A. Tubular Type (Method A) with the exception that the polyethylene encasement overlap must face away from the pull direction to avoid the under film accumulation of drilling mud and other foreign matter.

F. Attach pulling head to spigot end of the leading pipe length.


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G. Securely anchor the polyethylene tube to the end of the barrel of the leading pipe length by continuously taping the leading two feet of the barrel with overlapping tape wrap. Anchor the first wraps of tape directly on to the barrel of the pipe and extend the continuous taping on to the polyethylene encasement. For the remainder of the leading pipe length, overlap circumferential wraps of tape every one foot.

H. The drilling fluid and cuttings shall not enter under the polyethylene tube during the pull back or other operations. At assembled joints, the polyethylene overlap shall always have the forward pipe’s polyethylene tube overlap the next following pipe’s tube. The polyethylene on both sides of the joint shall be secured with circumferential wraps of tape or plastic tie straps.

I. Continue process by wrapping tape on each side of successive joints and every two feet along barrel.

J. Pipe-shaped Appurtenances: Cover bends, reducers, offsets, and other pipe-shaped appurtenances with polyethylene in same manner as pipe.

K. Odd-shaped Appurtenances: When it is not practical to wrap valves, tees, crosses, and other oddshaped pieces in tube, wrap with flat sheet or split length of polyethylene tube by passing sheet around appurtenance and encasing it. Make seams by bringing edges together, folding over twice, and taping down. At valve stems and other penetrations, secure polyethylene film with tape.

L. Openings in Encasement: Create openings for branches, saddles, service taps, blowoffs, air valves, and similar appurtenances by making an X-shaped cut in polyethylene and temporarily folding back film. After appurtenance is installed, tape slack securely to appurtenance and repair cut, as well as other damaged area in polyethylene, with tape.

M. Hydrant Drain Relief: For hydrant relief holes and similar orifices, apply 3 wraps of tape completely around the polyethylene encased pipe, then, with a utility knife, cut a hole in the tape and polyethylene that is 1-inch larger in diameter than the orifice/opening.

N. Direct Service Taps: For direct service taps, apply 3 wraps of tape completely around the polyethylene encased pipe to cover the area where the tapping machine and chain will be mounted. After the tapping machine is mounted, install the corporation stop directly through the tape and polyethylene. After the direct tap is completed, the entire circumferential area shall be closely inspected and repaired as needed.

O. Service Connections: Wrap service lines of copper and other dissimilar metals with polyethylene or suitable dielectric tape for a minimum clear distance of 3 feet away from the cast or ductile iron pipe. Surface preparation and method of application shall follow tape manufacturer’s written instructions.

P. Junctions between Wrapped and Unwrapped Pipe: Where polyethylene-wrapped pipe joins an adjacent pipe that is not wrapped, extend polyethylene wrap to cover adjacent pipe for at least 3 feet. Secure end with circumferential turns of tape.

Q. Installation of Pipe through Casings: Polyethylene encasement shall be used for pipe through casings. Use a single layer of polyethylene film. Casing spacers (insulated type) and casing end seals shall be installed. Do not damage the polyethylene film where these devices are attached to the pipe, over the encasement.


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3.3 REPAIRS

A. Repair any cuts, tears, punctures, or damage to polyethylene with adhesive tape or with short length of polyethylene sheet or cut open tube, wrapped around pipe to cover damaged area, and secured in place.

3.4 BACKFILL

A. Use the same backfill material as that specified for pipe without polyethylene wrap. Prevent damage to the polyethylene wrap when placing backfll. Assure backfill material is free from cinders, refuse, boulders, rocks, stones, or other material that could damage the polyethylene. Follow AWWA C600 for backfilling.


A. Freedom from Defects: All polyethylene film shall be clean, sound and free from defects.

B. Inspection: All parts of this Section are subject to inspection by Owner or its designated representative.

C. Non-Compliance: The Contractor will correct any deficiencies in materials or installation at his expense, including excavating the pipe subsequent to backfilling and re-installing the polyethylene wrap.

END OF SECTION


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PRECAST MANHOLES AND COVERS 02607-1

SECTION 02607

PRECAST MANHOLES AND COVERS

PART 1 - GENERAL


A. Precast concrete manholes.

B. Manhole frames and covers.


A. Section 02223 – Earthwork.

B. Section 02315 – Excavation, Trenching and Backfilling for Utilities.

C. Section 02240 – Dewatering and Drainage of Excavation.

1.3 REFERENCES

A. ASTM A48 - Gray Iron Castings.

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

C. ASTM C478 - Precast Reinforced Concrete Manhole Sections.

1.4 SUBMITTALS


B. Shop Drawings: Submit shop drawings indicating layout, unit locations, connection details, support items, dimensions, openings, and relationship to adjacent materials.

C. Design Data and Calculations.

D. Product Data: Submit product data indicating standard component configurations, design loads, deflections, cambers, and bearing requirements.

E. Manufacturer's Installation Instructions: Submit fabricator's installation instructions.

F. Indicate special procedures, surface preparation, and perimeter conditions requiring special attention.

PART 2 - PRODUCTS

2.1 MANHOLE SECTIONS

A. Where shown on the Drawings, Contractor shall furnish and install precast reinforced concrete manholes with cone tops, flat tops and flat slab bases conforming to the requirements of ASTM C-478.

B. Design of all sections shall be for HS-20 Loading.

C. Design calculations shall be submitted for precast reinforced concrete flat top slabs, wall sections, and flat slab bases to the Engineer for review.

D. All top sections for precast reinforced concrete manholes shall be supplied with factory-formed openings to accommodate the various size water mains.


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E. The joint between precast concrete sections shall be sealed with two rings of 100% butyl gasket in rope form having a square cross section of a nominal size of at least one-inch.

2.2 BOTTOM SLAB FOR MANHOLE

A. Bottom slabs for manholes shall be precast reinforced concrete integral base type. No slab or split bottom shall be used.

B. Design calculations shall be submitted to the Engineer, for review.

C. Precast reinforced concrete slab bottoms shall be installed on a six inch (6") cushion of FA-6 or crushed stone.

2.3 MANHOLE FRAMES AND COVERS

A. All castings shall be made from gray cast iron conforming to the requirements of AASHTO M105 Class 35B.

B. Castings intended for traffic service shall be clean castings capable of withstanding an application of 40,000 pound proof load as described in Section 5 of AASHTO M306 (includes items such as frames, grates, rings, covers, trench drainage, etc.)

C. Fabricate castings to conform to shapes, dimensions, and with wording or logos shown on Drawings.

D. All castings shall be manufactured in accordance with the requirement of Section 4 of AASHTO M306.

E. Testing shall be performed in accordance with the inspection criteria of AASHTO M306 and AASHTO M105.

F. Identification Markings:

1. Provide on all manhole lids.

2. All markings shall be subject to review by the Engineer.

a. Marking shall be "Water", "Sewer", "Electric", "Gas", and "Storm" as required.

b. All lids shall have the wording:

c. "DANGER: PERMIT-REQUIRED CONFINED SPACE DO NOT ENTER"

G. Manhole Steps.

1. All manhole steps provided for the Project must be fabricated from the same material and must meet minimum OSHA requirements.

2. Manhole steps shall be Neenah Foundry Co. R-1981-Y or approved equal.

H. Frames and covers shall be of the best quality of tough gray pig iron of uniform quality, free from blowholes, shrinkage, distortion or other defects. All castings shall be manufactured true to pattern; component parts shall fit together in a satisfactory manner. As cast dimensions may vary one-half the maximum shrinkage possessed by the metal or + 1/16 inch per foot. The castings shall be heated and dipped in hot asphaltic varnish.

2.4 RESILIENT CONNECTORS BETWEEN MANHOLE AND PIPE

The resilient connectors between the manhole and pipe shall meet the requirements of ASTM C923.


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PART 3 - EXECUTION

3.1 FIELD EXAMINATION

A. Verify that field conditions are acceptable and are ready to receive work.

3.2 INSTALLATION

A. Install castings and precast manholes in accordance with the Specifications and Drawings, shop drawings, and the manufacturer's installation instructions.

B. The casting placed on concrete surface shall be set in full mortar beds composed of one part masonry cement to two parts sand, by volume, based on dry materials, without other admixtures. Casting shall be set accurately to the finished elevation so that no subsequent adjustment will be necessary.

END OF SECTION


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CLEANING AND DISINFECTION OF WATER PIPING, EQUIPMENT AND FACILITIES 02675-1

SECTION 02675

CLEANING AND DISINFECTION OF WATER PIPING, EQUIPMENT AND FACILITIES



A. Cleaning and disinfection of water piping and water plants, including water containing structures, pumping equipment, and piping.

B. The Work includes, but is not limited to, the following:

1. Complete and thorough cleaning and disinfection of pumping equipment, pump suction and discharge piping, appurtenances, and plant yard piping.

2. Clean water flushing of all facilities.

3. Contractor shall be responsible for all required water sampling and laboratory testing. Contractor shall deliver all samples to Owner’s Representative. Owner’s Representative shall then deliver all samples to Owner-selected laboratory.

4. Quality Assurance, Quality Control, and Project Record Documents under this Section.


A. Work shall conform to applicable Texas Commission on Environmental Quality (TCEQ) regulations for Work in this Section.

B. Work shall be performed in accordance with AWWA C651, C652, C653, and C655.

C. Qualifications

1. Disinfection Firm: Company specializing in disinfecting potable water systems specified in this section with minimum three (3) years documented experience.

2. Testing Firm: Company specializing in testing potable water systems certified by the State of Texas.

3. Testing Laboratory: Certified for examination of drinking water in compliance with TCEQ. Testing laboratory shall be one of the following:

a. Nova Biologicals, Inc. 1775 North Loop 336 E Conroe, TX 77301 (800)282-5416

b. North Water District Laboratory Services, Inc. 8725 Fawn Trail The Woodlands, TX 77385 (936)321-6060


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1.3 SUBMITTALS

A. Test Reports: Indicate results comparative to specified requirements for Quality Assurance, Quality Control, and Project Record Documents.

B. Certificate: Certify that cleanliness of water facilities meets or exceeds requirements of TCEQ.

C. Disinfection Firm, Testing Firm, and Testing Laboratory qualifications.


A. Submit reports under provisions of Section 01330 – Submittal Procedures.

B. Disinfection Report, accurately record:

1. Method of chlorination and form of chlorine used.

2. Date and time of start of disinfectant injection and time of completion.

3. Test Locations.

4. Initial and 24-hour disinfectant residuals (quantity in treated water) in ppm for each outlet tested.

5. Date and time of start of flushing and time of completion.

6. Disinfectant residual after flushing in ppm for each outlet tested.

C. Bacteriological Report, accurately record:

1. Date issued, project name, and testing laboratory name, address, and telephone number.

2. Time and date of water sample collection.

3. Name of person collecting samples.

4. Test locations.

5. Initial and 24 hour disinfectant residuals in ppm for each outlet tested.

6. Coliform bacteria test results for each outlet tested.

7. Certification that water conforms, or fails to conform, to bacterial standards of TCEQ.

8. Bacteriologist's signature.

1.5 REFERENCES

A. AWWA C651 – Disinfecting Water Mains

B. AWWA C652 – Disinfection of Water Storage Facilities

C. AWWA C653 – Disinfection of Water Treatment Plants

D. AWWA C655 – Field Dechlorination

E. AWWA B300 – Hypochlorites

F. AWWA B301 – Liquid Chlorine


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2.1 DISINFECTION CHEMICALS

A. Liquid Chlorine.

1. Liquid Chlorine shall conform to requirements of AWWA B301.

B. Hypochlorite.

1. Hypochlorite shall conform to the requirements of AWWA B300.


3.1 PREPARATION

A. Verify that piping, pumping equipment, and water storage facilities have been cleaned, inspected, pressured tested and/or leakage tested.

B. Perform scheduling and disinfection activity with start-up, testing, adjusting, and balancing, and demonstration procedures, including coordination with related systems.

3.2 WATER PIPING

A. Piping delivering raw water shall be cleaned, but disinfection is not required.

B. The Work shall be done under the direction of the Engineer.

C. Chlorine shall be added to the water main after pressure testing has been completed.

D. Standard corporation cocks and copper tube gooseneck shall be furnished and installed at preferred points of application, as recommended by a disinfection expert.

E. The water main shall be completely cleaned of all foreign materials, but not flushed before disinfection.

F. The amount of chlorine applied shall be such as to provide a concentration of not less than 25 parts per million of available chlorine distributed uniformly through the length of the main being disinfected. It will be the Contractor's responsibility to take water samples after the 24 hours indicating a minimum of 10 ppm of chlorine remains present in the water main.

G. As an alternate to the above, the amount of chlorine applied shall be such as to provide a concentration of 100 ppm of available chlorine. The chlorine shall be applied continuously and for a sufficient period to form a solid column or a slug of chlorinated water that as it moves through the main exposes all interior surfaces to a concentration of approximately 100 ppm for at least 3 hours. The free chlorine residual shall be measured as the chlorinated water moves through the main. If at any time it drops below 50 ppm, the flow shall be stopped and the chlorinated water shall be restored to 100 ppm.

H. As chlorinated water flows past fittings and valves, the valves shall be operated so as to disinfect appurtenances and pipe branches.

I. Samples shall be collected from the main and shall be tested for bacteriological quality in accordance with AWWA C651- latest revisions.


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J. After testing and disinfecting, the pipeline shall be completely drained and left in a dry condition.

K. The method of disposal of highly chlorinated water shall be in conformance with AWWA C655 and comply with all applicable laws, regulations, statutes, and be acceptable to the TCEQ.

3.3 QUALITY CONTROL

A. Provide analysis and testing of treated water under provisions of Section 01380 – Quality Control.

B. Test samples in accordance to AWWA C651, C652, and C653.

END OF SECTION


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FLEXIBLE BASE COURSE FOR DRIVEWAYS 02714-1

SECTION 02714

FLEXIBLE BASE COURSE FOR DRIVEWAYS

PART 1 - GENERAL


A. Foundation course of crushed concrete or stone.

1.2 REFERENCES

A. ASTM D 1556 - Density of Soil in Place by the Sand-Cone Method.

B. ASTM D 698 - Standard Test Method for Laboratory Compaction Characteristics of Soil Using Standard Effort (12.44 ft-lbf/ft3).

C. ASTM D 2922 - Test Methods for Density of Soil and Soil-Aggregate in Place by Nuclear Methods (Shallow Depth).

D. ASTM D 361 - Test Method for Water Content of Soils and Rock in Place by Nuclear Methods (shallow depth).

E. ASTM D 3017 - Test Method for Water Content of Soils and Rock in Place by Nuclear Methods.

F. ASTM D 4318 - Test Method for Liquid Limit, Plastic Limit, and Plasticity Index of Soils.

G. TxDOT Tex-101-E - Preparation of Soil and Flexible Base Materials for Testing.

H. TxDOT Tex-110-E - Determination of Particle Size Analysis of Soils.

1.3 SUBMITTALS

A. Submittals shall conform to requirements of Section 01330 - Submittals Procedures.

B. Submit samples of flexible base course and soil binder for testing.

1.4 TESTS

A. Tests and analysis of soil materials will be performed in accordance with ASTM C 131, ASTM D 698, ASTM D 4318, Tex-101-E, and Tex-110-E under provisions of Section 01454 - Testing Laboratory Services.


A. Provide materials from stockpiles that are protected during storage from contaminates that would be detrimental to the flexible base course.

B. B. Load materials from same area of stockpile to maintain uniformity of each successive delivery to the project site.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Crushed Stone or Concrete: Material retained on the No. 40 sieve meeting the following requirements:

1. Durable particles of crusher-run broken limestone, crushed concrete, crushed sandstone, or granite obtained from an approved source.


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2. Los Angeles abrasion test percent of wear not to exceed 40 when tested in accordance with ASTM C 131.

B. Soil Binder: Material passing the No. 40 sieve meeting the following requirements when tested in accordance with ASTM D 4318:

1. Maximum Liquid Limit: 40

2. Maximum Plasticity Index: 12

3. Maximum Lineal Shrinkage: 7 (when calculated from volumetric shrinkage at liquid limit).

C. Mixed Materials shall meet the following requirements:

1. Minimum compressive strength of 35 psi at 0 psi lateral pressure and 175 psi at 15 psi lateral pressure using triaxial testing procedures.

2. Grading in accordance with Tex-101-E and Tex-110-E within the following limits:

Sieve Percent Retained

1 – 3/4 inch 0 to 10

No. 4 45 to 75

No 40 60 to 85

PART 3 - EXECUTION

3.1 EXAMINATION

A. Verify compacted subgrade is ready to support imposed loads.


3.2 PREPARATION

A. Complete backfill of new utilities below future grade.

B. Prepare subgrade in accordance with requirements Sections 02336 - Lime Stabilized Subgrade and 02337 - Lime/Fly-ash Stabilized Subgrade.

C. Correct subgrade deviations in excess of plus or minus 1/2 inch in cross section, or in 16 foot length by loosening, adding or removing material, reshaping and recompacting by sprinkling and rolling.

D. Prepare sufficient subgrade in advance of base course operations.

3.3 PLACEMENT

A. Spread and shape in lifts to compacted thickness not to exceed 4 inches in depth. Complete spreading, shaping, and compacting on same day material is deposited.

B. Place base so that projecting reinforcing steel from curbs remain at approximate center of base. Secure a firm bond between reinforcement and base.


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C. Start rolling operations as soon as possible after placement. Use sheepfoot, steel, or pneumatic rollers as approved. Roll longitudinally with subgrade starting from sides. Overlap successive strips by one-half width of each rear wheel.

D. Maintain moisture between optimum and 3 percent above optimum moisture.

E. Compact to 95 percent of Proctor density in accordance with ASTM D 698, unless otherwise indicated on the Drawings.

F. Finish to grade and compact lift before placing successive lift.

G. Maintain shape by grading throughout operation.

H. Provide total thickness indicated on Drawings.

3.4 TOLERANCES

A. Completed surface shall be smooth and conform to typical section and established lines and grades.



B. Compaction Testing will be performed in accordance with ASTM D 698 or ASTM D 2922 and ASTM 3017 at a random location near each depth determination core. Rework and recompact areas that do not conform to compaction requirements.

3.6 PROTECTION

A. Sprinkle to prevent excessive loss of moisture.

B. Restrict construction traffic on finished base to equipment required to complete the work.

END OF SECTION


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CONCRETE PAVING 02751-1

SECTION 02751

CONCRETE PAVING

PART 1 - GENERAL


A. Portland cement concrete paving.

1.2 REFERENCES

A. ASTM A82 - Standard Specification for Steel Wire, Plain, for Concrete Reinforcement.

B. ASTM A185 - Standard Specifications for Steel Welded Wire Fabric, Plain, for Concrete Reinforcement.

C. ASTM A497 – Standard Specification for Steel Welded Wire Reinforcement, Deformed, for Concrete.

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

E. ASTM C 31 - Standard Practice for Making and Curing Concrete Test Specimens in the Field.

F. ASTM C 33 - Standard Specifications for Concrete Aggregates.

G. ASTM C 39 - Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens.

H. ASTM C 40 - Standard Test Method for Organic Impurities in Fine Aggregates for Concrete.

I. ASTM C 42 - Standard Test Method of Obtaining and Testing Drilled Cores and Sawed Beams of Concrete.

J. ASTM C 78 - Standard Test Method for Flexural Strength of Concrete (Using Simple Beam with Third Point Loading).

K. ASTM C 94 - Standard Specification for Ready-Mixed Concrete.

L. ASTM C 131 - Standard Test Method for Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine.

M. ASTM C 136 - Standard Method for Sieve Analysis of Fine and Coarse Aggregates.

N. ASTM C 138 - Standard Test Method for Unit Weight, Yield, and Air Content (Gravimetric) of Concrete.

O. ASTM C 143 - Standard Test Method for Slump of Hydraulic Cement Concrete.

P. ASTM C 150 - Standard Specification for Portland Cement.

Q. ASTM C 174 - Standard Test Method for Measuring Thickness of Concrete Elements Using Drilled Concrete Cores.

R. ASTM C 231 - Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method.

S. ASTM C 260 - Standard Specification for Air-Entraining Admixtures for Concrete.


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T. ASTM C 494 - Standard Specification for Chemical Admixtures for Concrete.

U. ASTM C 618 - Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for use as a Mineral Admixture in Portland Cement Concrete.

V. TxDOT Tex-203-F - Sand Equivalent Test.

W. TxDOT Tex-406-A - Material Finer than 75 )m (No. 200) Sieve In Mineral Aggregates (Decantation Test for Cement Aggregates).

1.3 SUBMITTALS


B. Submit proposed mix design and test data for each type and strength of concrete in Work. Include proportions and actual flexural strength obtained from design mixes at required test ages.

C. Submit for approval manufacturer's description and characteristics for mixing equipment, and for traveling form paver, when proposed for use.

D. Submit manufacturer's certificates giving properties of reinforcing steel. Include certificate of compliance with ASTM A 82. Provide specimens for testing when required by Owner’s Representative.

1.4 HANDLING AND STORAGE

A. Do not mix different classes of aggregate without written permission of Owner’s Representative.

B. Class of aggregate being used may be changed before or during Work with written permission of Owner’s Representative. Comply new class with specifications.

C. Reject segregated aggregate. Before using aggregate whose particles are separated by size, mix them uniformly to grading requirements.

D. Reject aggregates mixed with dirt, weeds, or foreign matter.

E. Do not dump or store aggregate in roadbed.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Portland Cement:

1. Sample and test cement to verify compliance with Standards of ASTM C 150, Type I or Type III.

2. Bulk cement which meets referenced standards may be used when method of handling is approved by Owner’s Representative. When using bulk cement, provide satisfactory weighing devices.

3. Fly ash which meets standards of ASTM C 618 may be used as mineral fill when method of handling is approved by Owner’s Representative.

B. Water: Conform to requirements for water in ASTM C 94.


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C. Coarse Aggregate: Crushed stone, gravel, or combination thereof, which is clean, hard, and durable, conforms to requirements of ASTM C 33, and has abrasion loss not more than 45 percent by weight when subjected to Los Angeles Abrasion Test (ASTM C 131).

1. Maximum percentage by weight of deleterious substances shall not exceed following values:

Item Percent by Weight of

Total Sample Maximum

Clay lumps and friable particles Material finer than 75 – ȝm (No. 200) sieve: Concrete subject to abrasion All other concrete Coal and lignite: Where surface appearance of concrete is of

Importance All other concrete

3.0

3.0* 5.0*

0.5 1.0

In case of manufactured sand, when material finer than 75-ȝm (No. 200) sieve consists of dust of fracture, essentially free from clay or shale, these limits may be increased to 5 and 7 percent, respectively.

2. Conform coarse aggregate (size 1 1/2 inch to No. 4 sieve) to requirements of ASTM C

33. Use gradation within following limits when graded in accordance with ASTM C 136:

Sieve Designation (Square Openings) Percentage by Weight

Retained on 1 ¾” sieve Retained on 1 ½ “ sieve Retained on ¾’ sieve Retained on 3/8” sieve Retained on No. 4 sieve Loss by Decantation Test *Method Tex-406-A

0

0 to 5 30 to 65 70 to 90 95 to 100

1.0 maximum

In case of aggregates made primarily from crushing of stone, when material finer than 200 sieve is dust of fracture essentially free from clay or shale as established by Part III of TxDOT Tex-406-A, percent may be increased to 1.5.

D. Fine Aggregate: Sand, manufactured sand, or combination thereof, composed of clean, hard, durable, uncoated grains, free from loams or other injurious foreign matter. Conform fine aggregate for concrete to requirements of ASTM C 33. Use gradation within following limits when graded in accordance with ASTM C 136:


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Sieve Designation (Square Openings) Percentage by Weight Retained on 3/8” sieve 0 Retained on No. 4 sieve 0 to 20 Retained on No. 8 sieve 15 to 50 Retained on No. 16 sieve 35 to 75 Retained on No. 30 sieve 65 to 90 Retained on No. 50 sieve 65 to 90 Retained on No. 100 sieve 90 to 100 Retained on No. 200 sieve 97 to 100

1. When subjected to color test for organic impurities (ASTM C 40), fine aggregate shall not show color darker than standard color. Fine aggregate shall be subjected to Sand Equivalent Test (Tex-203-F). Sand equivalent value shall not be less than 80, unless higher value is shown on Drawings.

E. Mineral Filler: Type “C” or Type “F” fly ash of acceptable quality and meeting requirements of ASTM C 618 may be used as mineral admixture in concrete mixture. When fly ash mineral filler is used, store and inspect in accordance with ASTM C 618. Do not use fly ash in amounts to exceed 25 percent by weight of cementatious material in mix design. Cement content may be reduced when strength requirements can be met. Note: When fly ash is used, term "cement" is defined as cement plus fly ash.

F. Air Entraining Agent: Furnish air entraining agent conforming to requirements of ASTM C 260.

G. Water Reducer: Water reducing admixture conforming to requirements of ASTM C 494 may be used when required to improve workability of concrete. Amount and type of admixture is subject to approval by Owner’s Representative.

H. Reinforcing Steel:

1. Provide new billet steel manufactured by open hearth process and conforming to ASTM A 615, Grade 60. Store steel to protect it from mechanical injury and rust. At time of placement, steel shall be free from dirt, scale, rust, paint, oil, or other injurious materials.

2. Cold bend reinforcing steel to shapes shown. Once steel has been bent, it may not be rebent.

3. Provide wire fabric conforming to ASTM A 82. Use fabric in which longitudinal and transverse wires have been electrically welded at points of intersection. Welds shall have sufficient strength not to be broken during handling or placing. Conform welding and fabrication of fabric sheets to ASTM A 185.

2.2 EQUIPMENT

A. Conform Equipment to requirements of ASTM C94.


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2.3 MIXING

A. Flexural strength shall be as specified using test specimens prepared in accordance with ASTM C 31 and tested in accordance with ASTM C78 (using simple beam with third-point loading). Compressive strength shall be as specified using test specimens prepared in accordance with ASTM C 31 and tested in accordance with ASTM C 39. Determine and measure batch quantity of each ingredient, including water for batch designs and all concrete produced for Work. Mix shall conform to these specifications and other requirements indicated on Drawings.

B. Mix design to produce concrete which will have flexural strength of 500 psi at 7 days and 600 psi at 28 days. Minimum compressive strength shall be 3000 pounds per square inches for 7 days and 3500 pounds per square inches at 28 days when tested in accordance with ASTM C39. Slump of concrete shall be at least 2 inches but no more than 5 inches, when tested in accordance with ASTM C143.

1. Concrete pavement, including curb, curb and gutter, and saw-tooth curb, shall contain at least 5 1/2 sacks (94 pounds per sack) of cement per cubic yard, with not more than 6.5 gallons of water, net, per sack of cement (water-cement ratio maximum 0.57). Determine cement content in accordance with ASTM C 138. Addition of mineral filler may be used to improve workability or plasticity of concrete to limits specified.

2. Coarse dry aggregate shall not exceed 85 percent of loose volume of concrete.

3. Add air-entraining admixture to ensure uniform distribution of agent throughout batch. Base air content of freshly mixed air-entrained concrete upon trial mixes with materials to be used in Work, adjusted to produce concrete of required plasticity and workability. Percentage of air entrainment in mix shall be 4 1/2 percent plus or minus 1 1/2 percent. Determine air content by testing in accordance with ASTM C 231.

4. Use retardant when temperature exceeds 90 degrees F. Proportion as recommended by manufacturer. Use same brand as used for air-entraining agent. Add and batch material using same methods as used for air-entraining agent.

C. Use high early strength concrete pavement to limits shown on Drawings. Design to meet following:

1. Concrete Mix: Flexural strength greater than or equal to 500 psi at 72 hours.

2. Cement: Minimum of 7 sacks of cement per cubic yard of concrete.

3. Water-Cement Ratio maximum of 0.45. Slump of concrete shall a maximum of 5 inches, when tested in accordance with ASTM C 143.

4. Other requirements for proportioning, mixing, execution, testing, etc., shall be in accordance with this Section.


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PART 3 - EXECUTION

3.1 EXAMINATION

A. Verify compacted base is ready to support imposed loads and meets compaction requirements.


3.2 PREPARATION

A. Properly prepare, shape and compact each section of subgrade before placing forms, reinforcing steel or concrete. After forms have been set to proper grade and alignment, use subgrade planer to shape subgrade to its final cross section. Check contour of subgrade with template.

B. Remove subgrade that will not support loaded form. Replace and compact subgrade to required density.

3.3 EQUIPMENT

A. Alternate equipment and methods, other than those required by this Section, may be used provided equal or better results will be obtained. Maintain equipment for preparing subgrade and for finishing and compacting concrete in good working order.

B. Subgrade Planer and Template:

1. Use subgrade planer with adjustable cutting blades to trim subgrade to exact section shown on Drawings. Select planer mounted on visible rollers which ride on forms. Planer frame must have sufficient weight so that it will remain on form, and have strength and rigidity that, under tests made by changing support from wheels to center, planer will not develop deflection of more than 1/8 inch. Tractors used to pull planer shall not produce ruts or indentations in subgrade. When slip form method of paving is used, operate subgrade planer on prepared track grade or have it controlled by electronic sensor system operated from string line to establish horizontal alignment and elevation of subbase.

2. Provide template for checking contour of subgrade. Template shall be long enough to rest upon side forms and have strength and rigidity that, when supported at center, maximum deflection shall not exceed 1/8 inch. Fit template with accurately adjustable rods projecting downward at 1 foot intervals. Adjust these rods to gauge cross sections of slab bottom when template is resting on side forms.

C. Machine Finisher: Provide power-driven, transverse finishing machine designed and operated to strike off and consolidate concrete. Machine shall have two screeds accurately adjusted to crown of pavement and with frame equipped to ride on forms. Use finishing machine with rubber tires when it operates on concrete pavement.

D. Hand Finishing:

1. Provide mechanical strike and tamping template 2 feet longer than width of pavement to be finished. Shape template to pavement section.

2. Provide two bridges to ride on forms and span pavement for finishing expansion and dummy joints. Provide floats and necessary edging and finishing tools.


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E. Burlap Drag or transverse broom for Finishing Slab: Furnish four plies of 10 ounce burlap material fastened to bridge to form continuous strip of burlap full width of pavement. Maintain contact 3 foot width of burlap material with pavement surface. Keep burlap drags clean and free of encrusted mortar.

F. Vibrators: Furnish mechanically-operated, synchronized vibrators mounted on tamping bar which rides on forms and hand-manipulated mechanical vibrators. Furnish vibrators with frequency of vibration to provide maximum consolidation of concrete without segregation.

G. Traveling Form Paver: Approved traveling form paver may be used in lieu of construction methods employing forms, consolidating, finishing and floating equipment. Meet requirements of this specification for subgrade, pavement tolerances, pavement depth, alignments, consolidation, finishing and workmanship. When traveling form paver does not provide concrete paving that meets compaction, finish, and tolerance requirements of this Specification, immediately discontinue its use and use conventional methods.

1. Equip traveling paver with longitudinal transangular finishing float adjustable to crown and grade. Use float long enough to extend across pavement to side forms or edge of slab.

2. Ensure that continuous deposit of concrete can be made at paver to minimize starting and stopping. Use conventional means of paving locations inaccessible to traveling paver, or having horizontal or vertical curvature that traveling paver cannot negotiate.

3. Where Drawings require tie bars for adjacent paving, securely tie and support bars to prevent displacement. Tie bars may be installed with approved mechanical bar inserter mounted on traveling-form paver. Replace pavement in which tie bars assume final position other than that shown on Drawings.

3.4 FORMS

A. Side Forms: Use metal forms of approved shape and section. Preferred depth of form is equal to required edge thickness of pavement. Forms with depths greater or less than required edge thickness of pavement will be permitted, provided difference between form depth and edge thickness when not greater than 1 inch, and further provided that forms of depth less than pavement edge are brought to required edge thickness by securely attaching wood or metal strips to bottom of form, or by grouting under form. Bottom flange of form shall be same size as thickness of pavement. Aluminum forms are not allowed. Forms shall be approved by Owner’s Representative. Length of form sections shall be not less than 10 feet and each section shall provide for staking in position with not less than 3 pins. Flexible or curved forms of wood or metal of proper radius shall be used for curves of 200 foot radius or less. Forms shall have ample strength and shall be provided with adequate devices for secure setting so that when in-place they will withstand, without visible springing or settlement, impact and vibration of finishing machine. In no case shall base width be less than 8 inches for form 8 inches or more in height. Forms shall be free from warp, bends or kinks and shall be sufficiently true to provide straight edge on concrete. Top of each form section, when tested with straight edge, shall conform to requirements specified for surface of completed pavement.


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Provide sufficient forms for satisfactory placement of concrete. For short radius curves, forms less than 10 feet in length or curved forms may be used. For curb returns at street intersections and driveways, wood forms of good grade and quality may be used.

B. Form Setting:

1. Rest forms directly on subgrade. Do not shim with pebbles or dirt. Accurately set forms to required grade and alignment and, during entire operation of placing, compacting and finishing of concrete, do not deviate from this grade and alignment more than 1/8 inch in 10 feet of length. Do not remove forms for at least 8 hours after completion of finishing operations. Provide supply of forms that will be adequate for orderly and continuous placing of concrete. Set forms and check grade for at least 300 feet ahead of mixer or as approved by Owner’s Representative.

2. Adjacent slabs may be used instead of forms, provided that concrete is well protected from possible damage by finishing equipment. Do not use adjacent slabs for forms until concrete has aged at least 7 days.

3.5 REINFORCING STEEL AND JOINT ASSEMBLIES

A. Place reinforcing steel and joint assemblies and position securely as indicated on Drawings. Wire reinforcing bars securely together at intersections and splices. Bars and coatings shall be free of rust, dirt or other foreign matter when concrete is placed. Secure reinforcing steel to chairs.

B. Position pavement joint assemblies at required locations and elevations, and rigidly secure in position. Install dowel bars in joint assemblies, each parallel to pavement surface and to center line of pavement, as shown.

C. Cut header boards, joint filler, and other material used for forming joints to receive each dowel bar.

D. Secure in required position to prevent displacement during placing and finishing of concrete.

E. Drill dowels into existing pavement, secure with epoxy, and provide paving headers as required to provide rigid pavement sections.

F. Use sufficient number of chairs for steel reinforcement bars to maintain position of bars within allowable tolerances. Place reinforcement as shown on Drawings. In plane of steel parallel to nearest surface of concrete, bars shall not vary from plan placement by more than 1/12 of spacing between bars. In plane of steel perpendicular to nearest surface of concrete, bars shall not vary from plan placement by more than 1/4 inch.

3.6 FIBROUS REINFORCING

A. Do not use fibrous reinforcing to replace structural, load-bearing, or moment-reinforcing steel.

3.7 PLACEMENT

A. Place concrete when air temperature taken in shade and away from artificial heat is above 35 degrees F and rising. Do not place concrete when temperature is below 40 degrees F and falling.


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B. Place concrete within 90 minutes after initial water had been added. Remove and dispose of concrete not placed within this period.

C. Concrete slump during placement shall be 1 to 5 inches, except when using traveling-form paver, slump shall be maximum of 2 inches.

D. Deposit concrete continuously in successive batches. Distribute concrete in manner that will require as little rehandling as possible. Where hand spreading is necessary, distribute concrete with shovels or by other approved methods. Use only concrete rakes in handling concrete. At placement interruption of more than 30 minutes, place transverse construction joint at stopping point. Remove and replace sections less than 10 feet long.

E. Take special care in placing and spading concrete against forms and at longitudinal and transverse joints to prevent honeycombing. Voids in edge of finished pavement will be cause for rejection.

3.8 COMPACTION

A. Consolidate concrete using mechanical vibrators as specified herein. Extend vibratory unit across pavement, not quite touching side forms. Space individual vibrators at close enough intervals to vibrate and consolidate entire width of pavement uniformly. Mount mechanical vibrators to avoid contact with forms, reinforcement, transverse or longitudinal joints.

B. Furnish enough hand-manipulated mechanical vibrators for proper consolidation of concrete along forms, at joints and in areas not covered by mechanically controlled vibrators.

3.9 FINISHING

A. Finish concrete pavement with power-driven transverse finishing machines or by hand finishing methods.

1. Hand finish with mechanical strike and tamping template in same width as pavement to be finished. Shape template to pavement section shown on Drawings. Move strike template forward in direction of placement, maintaining slight excess of material in front of cutting edge. Make minimum of two trips over each area. Screed pavement surface to required section. Work screed with combined transverse and longitudinal motion in direction work is progressing. Maintain screed in contact with forms. Use longitudinal float to level surface.

B. On narrow strips and transitions, finish concrete pavement by hand. Thoroughly work concrete around reinforcement and embedded fixtures. Strike off concrete with strike-off screed. Move strike-off screed forward with combined transverse and longitudinal motion in direction work is progressing, maintaining screed in contact with forms, and maintaining slight excess of materials in front of cutting edge. Tamp concrete with tamping template. Use longitudinal float to level surface.

C. After completion of straightedge operation, make first pass of burlap drag or transverse broom as soon as construction operations permit and before water sheen has disappeared from surface. Follow with as many passes as required to produce desired texture depth. Permit no unnecessary delays between passes. Keep drag wet, clean and free from encrusted mortar during use.


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3.10 JOINTS AND JOINT SEALING

A. Conform to requirements of Section 02752 - Concrete Pavement Joints.

3.11 CONCRETE CURING

A. Conform to requirements of Section 02753 - Concrete Pavement Curing.

3.12 TOLERANCES

A. Test entire surface before initial set and correct irregularities or undulations. Bring surface within requirements of following test and then finish. Place 10 foot straightedge parallel to center of roadway to bridge depressions and touch high spots. Do not permit ordinates measured from face of straight edge to surface of pavement to exceed 1/16 inch per foot from nearest point of contact. Maximum ordinate with 10 foot straightedge shall not exceed 1/8 inch. Grind spots in excess of required tolerances to meet surface test requirements. Restore texture by grooving concrete to meet surface finishing specifications.


A. Perform testing under provisions of Section 01380 – Quality Conrol.

B. Compressive Strength Test Specimens: Make four test specimens for compressive strength test in accordance with ASTM C 31 for each 150 cubic yards or less of pavement that is placed in one day. Test two specimens at 7 days or at number of hours as directed by the Owner’s Representative for high early strength concrete. Test remaining two specimens at 28 days. Test specimens in accordance with ASTM C 39. Minimum compressive strength shall be 3000 pounds per square inch for first two specimens and 3500 pounds per square inch at 28 days.

C. When compressive test indicates failure, make yield test in accordance with ASTM C 138 for cement content per cubic yard of concrete. When cement content is found to be less than that specified per cubic yard, increase batch weights until amount of cement per

D. Minimum of one 4 inch core will be taken at random locations per 375 feet per 12 feet lane or 500 square yards of pavement to measure in-place depth. Measure depth in accordance with ASTM C 174. Each core may be tested for 28 day compressive strength according to methods of ASTM C 42. 28 day compressive strength of each core tested shall be a minimum of 3000 pounds per square inch.

E. Request, at option, three additional cores in vicinity of cores indicating nonconforming in-place depths at no cost to City. In-place depth at these locations shall be average depth of four cores.

F. Fill cores and density test sections with new concrete paving or non-shrink grout.

3.14 NONCONFORMING PAVEMENT

A. Remove and replace areas of pavement found deficient in thickness by more than 10 percent, or that fail compressive strength tests, with concrete of thickness shown on Drawings.


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B. When measurement of any core is less than specified thickness by more than 10 percent, actual thickness of pavement in this area will be determined by taking additional cores at 10 foot intervals parallel to centerline in each direction from deficient core until, in each direction, core is taken which is not deficient by more than 10 percent. Exploratory cores

for deficient thickness will not be used in averages for adjusted unit price. Exploratory

cores are to be used only to determine length of pavement in unit that is to be removed

and replaced. Replace nonconforming pavement sections at no additional cost to City.

3.15 UNIT PRICE ADJUSTMENT

A. Unit price adjustments shall be made for in-place depth determined by cores as follows:

1. Adjusted Unit Price shall be ratio of average thickness as determined by cores to thickness bid upon, times unit price.

2. Apply adjustment to lower limit of 90 percent and upper limit of 100 percent of unit price.

3. Average depth below 90 percent but greater than 80 percent may be accepted by Owner’s Representative at adjusted Unit Price of:

a) Unit Price Bid - [2 x (1-ratio) x Unit Price Bid]

b) Ratio equals average core thickness divided by thickness bid upon

c) 0.9 ratio pays 80 percent of unit price and 0.8 ratio pays 60 percent of unit price.

d) Average depth below 80 percent will be rejected by Owner’s Representative.

3.16 PAVEMENT MARKINGS

A. Restore pavement markings to match those existing in accordance with City of Conroe standard specifications and details and Owner’s Representative's requirements.

3.17 PROTECTION

A. Barricade pavement section to prevent use until concrete has attained minimum design strength. Cure barricade pavement section for minimum 72 hours before use. Do not open pavement to traffic until concrete is at least 10 days old. Pavement may be open to traffic earlier provided Contractor pays for testing and additional specimen once 7 day specified strength is obtained. Pavement may be opened when high early strength concrete is used meeting specified 72 hour strength.

B. High early strength concrete may be used to provide access at driveways, street intersections, esplanades and other locations approved by Owner’s Representative.

C. On those sections of pavement to be opened to traffic, seal joints, clean pavement, and place earth against pavement edges before permitting use by traffic. Opening of pavement to traffic shall not relieve responsibility for Work.

D. Maintain concrete paving in good condition until completion of Work.

E. Repair defects by replacing concrete to full depth.

END OF SECTION


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CONCRETE PAVEMENT JOINTS 02752-1

SECTION 02752

CONCRETE PAVEMENT JOINTS

PART 1 - GENERAL


A. Joints for concrete paving; concrete sidewalks, concrete driveways, curbs, and curb and gutters.

B. Saw-cutting existing concrete or asphalt pavements for new joints.

1.2 REFERENCES

A. ASTM A 615 - Standard Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcement.

B. ASTM D 994 - Standard Specification for Preformed Expansion Joint Filler for Concrete (Bituminous Type).

C. ASTM D 1751 - Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types).

D. ASTM D 3405 - Standard Specification for Joint Sealants, Hot-Applied, for Concrete and Asphalt Pavements.

E. TxDOT Tex-525-C - Tests for Asphalt and Concrete Joint Sealers

1.3 SUBMITTALS


B. Submit product data for joint sealing compound and proposed sealing equipment for approval.

C. Submit samples of dowel cup, metal supports, and deformed metal strip for approval. Submit manufacturer's recommendation for placing sealant(s).

PART 2 - PRODUCTS

2.1 BOARD EXPANSION JOINT MATERIAL

A. Filler board of selected stock. Use wood of density and type as follows:

1. Clear, all-heart cypress weighing no more than 40 pounds per cubic foot, after being oven dried to constant weight.

2. Clear, all-heart redwood weighing no more than 30 pounds per cubic foot, after being oven dried to constant weight.

2.2 PREFORMED EXPANSION JOINT MATERIAL

A. Bituminous fiber and bituminous mastic composition material conforming to ASTM D 994 and ASTM D 1751.

2.3 JOINT SEALING COMPOUND

A. Conform joint sealants to one of sealant classes described in this section.

B. Conform hot-poured rubber-asphalt compound to ASTM D 3405.


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C. Two-component Synthetic Polymer.

1. Curing is to be by polymerization and not by evaporation of solvent or fluxing of harder particles.

2. Cure sufficiently at average temperature of 25° C (77° F) so as not to pick up under wheels of traffic in maximum three hours.

3. Performance requirements, when tested in accordance with TxDOT Tex-525-C, shall meet above curing times and requirements as follows:

Cold-Extruded and Cold-Pourable (Self-Leveling) Specifications

Property Requirement

Penetration, 25°C (77°F) 150 g Cone, 5 s, 0.1 mm (in.), maximum 130

Bond and Extension 50%, -29° C (-20° F), 3 cycles: Dry Concrete Block Steel blocks (Primed, if recommended by manufacturer) *Steel blocks shall be used when armor joints are specified

Pass Pass

Flow at 70° C (158° F) None

Water content % by mass, maximum 5.0

Resilience: Original sample, % min. (cured) Oven-aged at 70° C (158° F), % min.

50 50

Cold-extruded material only - Cold Flow (10 minutes) None

After bond and extension test, there shall be no evidence of cracking, separation or other opening that is over 3 millimeters (1/8 inch) deep in sealer or between sealer and test blocks.

4. Provide cold-extruded type for vertical or sloping joints.

5. Provide self-leveling type for horizontal joints.

D. Self-Leveling, Low Modulus Silicone or Polyurethane Sealant for Asphaltic Concrete and Portland Cement Concrete Joints. This shall be a single component self-leveling silicone or polyurethane material that is compatible with both asphalt and concrete pavements. The sealer shall not require a primer for bond; a backer rod shall be required which is compatible with the sealant; no reaction shall occur between rod and sealant.

When tested in accordance with TxDOT Tex-525-C, self-leveling sealant shall meet following requirements:


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Self-Leveling, Low Modulus Silicone or Polyurethane Sealant

Property Requirements

Tack Free Time, 25°C (77°F), minutes 120 maximum

Nonvolatile content, % by mass 93 minimum

Tensile Strength and 24 Hour Extension Test: Initial, 10-day cure, 25°C (77°F), kPa (psi) After Water Immersion, kPa (psi) After Heat Aging, kPa (psi) After Cycling, -29° C (-20° F), 50%, 3 cycles, kPa (psi) 24 Hour Extension

21 to 69 (3 to 10) 21 to 69 (3 to 10) 21 to 69 (3 to 10) 21 to 69 (3 to 10) Pass (All Specimens) After 24 hours, there shall be no evidence of cracking, separation or other opening that is over 3 mm (1/8 in.) deep at any point in the sealer or between the sealer and test blocks.

2.4 LOAD TRANSMISSION DEVICES

A. Smooth, steel dowel bars conforming to ASTM A 615, Grade 60. When indicated on Drawings, encase one end of dowel bar in approved cap having inside diameter 1/16 inch greater than diameter of dowel bar.

B. Deformed steel tie bars conforming to ASTM A 615, Grade 60.

2.5 SUPPORTS FOR REINFORCING STEEL AND JOINT ASSEMBLY

A. Employ supports of approved shape and size that will secure reinforcing steel and joint assembly in correct position during placing and finishing of concrete. Space supports as directed by Owner’s Representative.

PART 3 - EXECUTION

3.1 PLACEMENT

A. When new Work is adjacent to existing concrete, place joints at same location as existing joints in adjacent pavement.

B. If limit of removal of existing concrete or asphalt pavement does not fall on existing joint, saw cut existing pavement minimum of 2 inches deep to provide straight, smooth joint surface without chipping, spalling or cracks.

3.2 CONSTRUCTION JOINTS

A. Place transverse construction joint wherever concrete placement must be stopped for more than 30 minutes. Place longitudinal construction joints at interior edges of pavement lanes using No. 6 deformed tie bars, 30 inches long and spaced 18 inches on centers.


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3.3 EXPANSION JOINTS

A. Place 3/4 inch expansion joints at radius points of curb returns for cross street intersections, or as located in adjacent pavement but no further than 80 feet apart. Use no boards shorter than 6 feet. When pavement is 24 feet or narrower, use not more than 2 lengths of board. Secure pieces to form straight joint. Shape board filler accurately to cross section of concrete slab. Use load transmission devices of type and size shown on Drawings unless otherwise specified or shown as "No Load Transfer Device." Seal with joint sealing compound.

3.4 CONTRACTION JOINTS

A. Place contraction joints at same locations as in adjacent pavement or at spaces indicated on Drawings. Place smoothed, painted and oiled dowels accurately and normal to joint. Seal groove with joint sealing compound.

3.5 LONGITUDINAL WEAKENED PLANE JOINTS

A. Place longitudinal weakened plane joints at spaces indicated on Drawings. If more than 15 feet in width is poured, longitudinal joint must be saw cut. Seal groove with joint sealing compound.

3.6 SAWED JOINTS

A. Use sawed joints as alternate to contraction and weakened plane joints. Use circular cutter capable of cutting straight line groove minimum of 1/4 inch wide. Maintain depth of one quarter of pavement thickness. Commence sawing as soon as concrete has hardened sufficiently to permit cutting without chipping, spalling or tearing and prior to initiation of cracks. Once sawing has commenced, continue until completed. Make saw cut with one pass. Complete sawing within 24 hours of concrete placement. Saw joints at required spacing consecutively in sequence of concrete placement.

B. Concrete Saw: Provide sawing equipment adequate in power to complete sawing to required dimensions and within required time. Maintain ample supply of saw blades at work site during sawing operations. Maintain sawing equipment on job during concrete placement.

3.7 JOINTS FOR CURB, CURB AND GUTTER

A. Place 3/4 inch preformed expansion joints through curb and gutters at locations of expansion and contraction joints in pavement, at end of radius returns at street intersections and driveways, and at curb inlets. Maximum spacing shall be 120-foot centers.

3.8 JOINTS FOR CONCRETE SIDEWALKS

A. Provide 3/4 inch expansion joints conforming to ASTM A 1751 along and across sidewalk at back of curbs, at intersections with driveways, steps, and walls; and across walk at intervals not to exceed 36 feet. Provide expansion joint material conforming to ASTM D 994 for small radius curves and around fire hydrants and utility poles. Extend expansion joint material full depth of slab.


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3.9 JOINTS FOR CONCRETE DRIVEWAYS

A. Provide 3/4-inch expansion joints conforming to ASTM D 1751 across driveway in line with street face of sidewalks, at existing concrete driveways, and along intersections with sidewalks and other structures. Extend expansion joint material full depth of slab.

3.10 JOINT SEALING

A. Seal joints only when surface and joints are dry, ambient temperature is above 50 degrees F and less than 85 degrees F and weather is not foggy or rainy.

B. Use joint sealing equipment in like new working condition throughout joint sealing operation, and be approved by Owner’s Representative. Use concrete grooving machine or power-operated wire brush and other equipment such as plow, brooms, brushes, blowers or hydro or abrasive cleaning as required to produce satisfactory joints.

C. Clean joints of loose scale, dirt, dust and curing compound. The term joint includes wide joint spaces, expansion joints, dummy groove joints or cracks, either preformed or natural. Remove loose material from concrete surfaces adjacent to joints.

D. Fill joints neatly with joint sealer to depth shown. Pour sufficient joint sealer into joints so that, upon completion, surface of sealer within joint will be 1/4 inch above level of adjacent surface or at elevation as directed.

3.11 PROTECTION

A. Maintain joints in good condition until completion of Work.

B. Replace damaged joints material with new material as required by this Section.

END OF SECTION


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CONCRETE PAVEMENT CURING 02321-1

SECTION 02753

CONCRETE PAVEMENT CURING

PART 1 - GENERAL


A. Curing of Portland cement concrete paving.

1.2 REFERENCES

A. ASTM C 156 - Standard Test Method for Water Retention by Concrete Curing Materials.

B. ASTM C 171 - Standard Specifications for Sheet Materials for Curing Concrete.

C. ASTM C 309 - Standard Specifications for Liquid Membrane-Forming Compounds for Curing Concrete.

1.3 SUBMITTALS


B. Submit manufacturer's product data for cover materials and liquid membrane-forming compounds.

PART 2 - PRODUCTS

2.1 COVER MATERIALS FOR CURING

A. Conform curing materials to one of the following:

1. Polyethylene Film: Opaque pigmented white film conforming to requirements of ASTM C 171.

2. Waterproofed Paper: Paper conforming to requirements of ASTM C 171.

3. Cotton Mats: Single layer of cotton filler completely enclosed in cover of cotton cloth. Mats shall contain not less than 3/4 of a pound of uniformly distributed cotton filler per square yard of mat. Cotton cloth used for covering materials shall weigh not less than 6 ounces per square yard. Stitch mats so that mat will contact surface of pavement at all points when saturated with water.

2.2 LIQUID MEMBRANE-FORMING COMPOUNDS

A. Conform liquid membrane-forming compounds to ASTM C 309. Membrane shall restrict loss of water to not more than 0.55 kg/m2 in 72 hours using test method ASTM C 156.

PART 3 - EXECUTION

3.1 CURING REQUIREMENT

A. Cure concrete pavement by protecting against loss of moisture for period of not less than 72 hours immediately upon completion of finishing operations. Do not use membrane curing for concrete pavement to be overlaid by asphalt concrete.

B. Failure to provide sufficient cover material shall be cause for immediate suspension of concreting operations.


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CONCRETE PAVEMENT CURING 02321-2

3.2 POLYETHYLENE FILM CURING

A. Immediately after finishing surface, and after concrete has taken its initial set, apply water in form of fine spray. Cover surface with polyethylene film so film will remain in direct contact with surface during specified curing period.

B. Cover entire surface and both edges of pavement slab. Overlap joints in film sheets minimum of 12 inches. Immediately repair tears or holes occurring during curing period by placing acceptable moisture-proof patches or replacing.

3.3 WATERPROOFED PAPER CURING

A. Immediately after finishing surface, and after concrete has taken its initial set, apply water in form of fine spray. Cover surface with waterproofed paper so paper will remain in direct contact with surface during specified curing period.

B. Prepare waterproofed paper to form blankets of sufficient width to cover entire surface and both edges of pavement slab, and not be more than 60 feet in length. Overlap joints in blankets caused by joining paper sheets not less than 5 inches and securely seal with asphalt cement having melting point of approximately 180 degrees F. Place blankets to secure overlap of at least 12 inches. Immediately repair tears or holes appearing in paper during curing period by cementing patches over defects.

3.4 COTTON MAT CURING

A. Immediately after finishing surface, and after concrete has taken its initial set, completely cover surface with cotton mats, thoroughly saturated before application, maintaining contact with surface of pavement equally at all points.

B. Keep mats on pavement for specified curing period. Keep mats saturated so that, when lightly compressed, water will drip freely from them. Keeps banked earth or cotton mat covering edges saturated.

3.5 LIQUID MEMBRANE-FORMING COMPOUNDS

A. Immediately after free surface moisture, and after concrete has dispersed, apply liquid membrane-forming compound in accordance with manufacturer's instructions.

B. Moisten concrete by water fogging prior to application of membrane when surface has become dry.

C. Seal concrete surface with single coat at rate of coverage recommended by manufacturer and directed by Owner’s Representative, but not less than one gallon per 200 square feet of surface area.

3.6 TESTING MEMBRANE

A. Treated areas will be visually inspected for areas of lighter color of dry concrete as compared to dump concrete. Test suspected areas by placing few drops of water on surface. Membrane passes test when water stands in rounded beads or small pools which can be blown along surface of concrete without wetting surface.

B. Reapply membrane compound immediately at no cost to City when membrane fails above test.

END OF SECTION


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CONCRETE SIDEWALKS 02775-1

SECTION 02775

CONCRETE SIDEWALKS

PART 1 - GENERAL

1.1 SUMMARY

A. Provide 6-inch-thick concrete sidewalks in conformity with the lines, grades and details shown on drawings. Construct on an approved sand bed.

B. Replace sidewalks which are removed or damaged during construction. Replace with a sidewalk of width equivalent to the one removed or damaged.

PART 2 - PRODUCTS

2.1 CONCRETE

Provide materials and proportions for concrete which conform to the applicable requirements of Section 02751 – Concrete Paving.

2.2 EXPANSION JOINT FILLER

Meet requirements for expansion joint material specified in Section 02752 – Concrete Pavement Joints.

2.3 SAND BED

Use sand conforming to bank sand specified in Section 02223 – Earthwork.

PART 3 - EXECUTION

3.1 PREPARATION

A. Subgrade. Excavate subgrade 6 inches beyond the outside lines of the sidewalk. Shape to the line, grade and cross section. Compact the subgrade to a minimum of 95 percent AASHTO density at optimum moisture content, using Test Method T-99.

B. Sand Bed. Immediately after subgrade is prepared, cover with a 2-inch thick compacted sand bed. Lay concrete when sand is moist.

C. Forms. Use wood or metal forms with the proper section. Select pieces which are straight, unwarped and nominally 4 inches deep. Securely stake forms to line and grade and maintain in true position during concrete placement.

3.2 EXPANSION JOINTS

Provide 3/4-inch expansion joints along and across the sidewalk at the back of curbs, at intersections with steps and walls, and across the walk at intervals of 36 feet or less throughout


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CONCRETE SIDEWALKS 02775-2

the entire length of the sidewalk. Extend the expansion joint filler the full depth of the slab and the entire width of the walk.

3.3 PLACING AND FINISHING

A. Placing. Place the concrete in forms to the specified depth and tamp thoroughly with a "jitterbug" tamp to bring the mortar to the surface.

B. Finishing. Strike off to a smooth finish with a wood strike board. Finish smoothly with a wood hand float. Brush across the sidewalk lightly with a fine-haired brush.

C. Tool Joints. Unless otherwise shown on drawings, mark off walks 1/4 inch deep, at spacing equal to the width of the walk. Use a joint tool as wide as an edging tool. Finish the edges with a tool having 1/4-inch radius.

3.4 CURING AND PROTECTION

Cover the sidewalk with burlap or suitable cotton mats. Keep the cover wet for 48 hours after the burlap or mats are placed. Commence curing as soon as the concrete has hardened sufficiently to be unmarked by the method of curing. Instead of sprinkling, membrane curing methods may be used. Refer to the section on Portland Cement Concrete Pavement. Protect sidewalks from traffic for 48 hours after pouring.

3.5 BACKFILLING

After the concrete has set sufficiently, refill the space along the sides of the sidewalk to the top of the walk with suitable material. Tamp until firm and solid. Dispose of excess material as prescribed under the section on Earthwork.

END OF SECTION


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TREE, PLANT, AND HARDSCAPE PROTECTION 02912-1

SECTION 02912

TREE, PLANT, AND HARDSCAPE PROTECTION

PART 1 - GENERAL


A. Tree root barriers; various depths and combinations may be required

B. Tree trunk protectors.

C. Water barriers.

D. Staking and guying materials.

1.2 MEASUREMENT AND PAYMENT

A. Unit Prices

1. Payment for root barrier shall be on a linear foot basis for height noted.

2. Payment for tree trunk protector, water barriers and staking material shall be on a linear foot basis for height noted.

3. Refer to Section 01270 – Measurement and Payment for unit price procedures.

B. Stipulated Price (Lump Sum). When contract is Stipulated Price Contract, payment for Work in this Section is included in total Stipulated Price.

1.3 REFERENCES

A. Standards of the following as referenced:

1. American National Standards Institute (ANSI).

2. American Society for Testing and Materials (ASTM).

1.4 DEFINITIONS

A. Terms:

1. Tree root barrier: Mechanical barrier and root deflector to prevent tree roots from damaging hardscapes and landscapes.

2. Tree trunk protector: Material to protect young tree trunks from rodents, string trimmers, and lawn mowers.

3. Water barriers:

a. Controls run-off, preventing hardscape damage.

b. Prevents irrigation water from percolating under pavement.

c. Water corral for planting areas preventing pavement damage and saves water.

d. Prevents snow, ice, and saltwater run-off from polluting planting areas adjacent to roadways and parking areas.

e. Liner to separate golf greens and turf.

f. Bamboo control.

1.5 SUBMITTALS

A. Product data: Manufacturers standard literature defining materials for use on this Project.


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B. Shop drawings:

1. Indicate locations and extend for tree root barrier material.

2. Indicate trees receiving tree trunk protectors.

3. Indicate locations and extend of water barriers.

4. Indicate trees and plants to be staked and guyed.

C. Samples; if required by Engineer:

1. Tree root barrier: One full length panel.

2. Tree trunk protector: One unit.

3. Water barrier: One lineal foot of material.

4. Staking and guying: One lineal foot.

D. Quality control submittals; manufacturer’s instructions: Complete installation instructions for each item specified; may be combined with product data.


A. Qualifications; manufacturer: Minimum 20 years’ experience in tree and plant protection and accessories.


A. Packing and shipping: Provide materials in original unopened containers with manufacturer’s labels intact and legible.

B. Acceptance at site:

1. Damaged materials determined by visual inspection will not be accepted.

2. Remove rejected materials from Project site immediately.

C. Storage and protection: Store materials in dry area in manufacturer’s protective packaging; in original containers with labels and instructions intact.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Acceptable manufacturers:

1. Products of manufacturers meeting indicated standards and specified materials properties are acceptable for use, subject to approval of product list and samples.

B. Basic Material Properties of Tree Root Barriers

Material and Thickness Homopolymer Polyethylene

Properties ASTM Test Method Value Homopolymer Polyethylene

Tensile Stress Yield D638 3800

Elongation at Break % D638 10%

Tensile Modulus D638 155,000

Notched Izod Impact D256A 0.4 – 0.4

Flexural Modulus 73 PSI 0790 145,000

Hardness Shore D2240 P66


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2.2 MANUFACTURED UNITS

A. Tree root barriers:

1. Shall be produced 12” – 48” deep.

2. Material: 0.080” wall thickness, nominal, injection molded 50% post-consumer recycled polypropylene panels with UV inhibitors.

3. Panel Specifics:

a. 7/16” wide integral molded 0.08” thickness double top edge with stiffening ribs; bottom edge attached to vertical root deflecting ribs.

b. Integral molded 0.080” thickness by 2” deep vertical root directing ribs spaced at 6.00” O.C.

c. Integral molded 0.080” thickness by 2” long by 3/8” wide horizontal anti-lift ground lock tabs; minimum three per panel.

4. Preassembled joiner system for panel connection to adjacent panel.

5. Refer to standard details for root barrier installation.

B. Tree trunk protectors:

1. Material: 0.060” thickness polyethylene with UV inhibitors, recyclable.

2. Size: 9” high by single length accommodating tree up to 4” dia.

3. Larger trees indicated for protection: Couple two or more sections together.

C. Water barriers:

1. Product standard of quality: Water Barrier WB Series.

2. Material: 0.030” – 0.040” thickness High Density Polyethylene (HDPE)

3. Sizes: 24”, 30”, and 36” wide by 300’-0” rolls.

4. Manufacturer’s standard sealing tape.

5. Sealant: Silicone type recommended by water barrier manufacturer for certain applications; applications requiring sealant indicated in manufacturers product data.

D. Staking and guying materials:

1. Material: Flat, woven polypropylene, 900 lb. break strength.

2. Size: wide by manufacturer’s standard roll lengths.

2.3 ACCESSORIES

A. Provide related materials for complete installation of specified materials.


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PART 3 - EXECUTION

3.1 EXAMINATION

A. Verification of conditions:

1. Verify other work in other section, in, at, and around landscaping work is complete to extend that no damage will occur to newly planted materials or, any possible construction related damage will be minimal and replacement plant material is readily available for planting at no additional cost.

2. Obtain verification, in writing, from work required in other Sections directly involving work in this Section regarding correct grades have been provided, coordination of topsoil spreading, and lawns and grasses planting.

3. The contractor shall fulfill the responsibilities below prior to beginning work. Failure to do so will require removal or replanting work in this section.

a. Provide written notification to Engineer of unacceptable conditions

b. Receive verification of written notice

3.2 PREPARATION

A. Surface protection: Use methods necessary to prevent damage to completed site work performed in other Sections. Protect access to and areas around planted materials. Restore damaged areas to original compaction, grades and lines; repair damaged grassed areas.

3.3 INSTALLATION

A. Tree root barriers: Install in accord with manufacturers reviewed installation instruction where indicated on reviewed shop drawings with vertical root directing ribs facing inwards towards trees or plants; connect panels together as required.

B. Tree trunk protectors:

1. Install in accord with manufacturers reviewed installation instructions where indicated on reviewed shop drawings.

2. Join two or more segments together for trees over 4” dia.

C. Water barriers:

1. Install where indicated on reviewed shop drawings in accord with manufacturers reviewed installation instruction using material widths required for conditions encountered.

2. Seal to hardscape surfaces with specified sealant.

3. Join material lengths with manufacturers sealing tape.

D. Staking and guying materials

1. Immediately after planting, guy and stake designated trees and large plants.

2. Include tightening of guying materials to bring trees and plants to upright position.

END OF SECTION


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LANDSCAPE GRADING 02923-1

SECTION 02923

LANDSCAPE GRADING

PART 1 - GENERAL


Final grade topsoil for finish landscaping.


A. Section 01380 - Quality Control.

B. Section 02211 - Rough Grading.

C. Section 02315 - Excavation, Trenching and Backfilling for Utilities.

D. Section 02936 - Topsoiling and Seeding.

1.3 SAMPLES

A. Submit samples under provisions of Section 01380.

B. Submit 1 cubic yard sample of imported fill to site for inspection by Engineer.

1.4 PROTECTION

A. Protect landscaping and other features remaining as final Work.

B. Protect structures, fences, roads, sidewalks, paving, curbs, hydrants, and manholes.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Topsoil: Stored topsoil from site clearing may be reused as quantities allow.

B. Additional Topsoil: Imported, friable loam; free of subsoil, roots, grass, excessive amounts of weeds, stones, and foreign matter; acidity range (pH) between 5.5 and 7.5; with organic matter between 4% and 25%.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Verify that building and trench backfilling have been inspected.

B. Verify substrate base has been contoured and compacted.

3.2 SUBSTRATE PREPARATION

A. Eliminate uneven areas and low spots.

B. Remove debris, roots, branches, stones, in excess of 1/2 inch in size. Remove subsoil contaminated with petroleum products.


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LANDSCAPE GRADING 02923-2

C. Scarify subgrade to depth of 3 inches where topsoil is scheduled. Scarify areas where equipment was used for hauling and spreading topsoil and subsoil is compacted.

3.3 PLACING TOPSOIL

A. Place topsoil in areas where planting to a minimum depth of 4 inches. Place topsoil during dry weather.

B. Fine grade topsoil eliminating rough or low areas. Maintain profiles and contour of subgrade.

C. Remove roots, weeds, rocks and foreign material while spreading.

D. Manually spread topsoil close to trees, plants, and buildings to prevent damage. Lightly compact placed topsoil.

E. Remove surplus subsoil and topsoil from site.

F. Leave stockpile area and site clean and raked, ready to receive landscaping.

3.4 TOLERANCES

Top of Topsoil: Plus or minus 1/2 inch.

3.5 PROTECTION

A. Protect landscaping and other features remaining as final work.

B. Protect existing structures, fences, sidewalks, utilities, paving and curbs.

END OF SECTION


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TOPSOILING AND SEEDING 02936-1

SECTION 02936

TOPSOILING AND SEEDING

PART 1 - GENERAL


A. Scope:

1. Contractor shall furnish and provide seeding as shown and specified.

2. All graded areas and areas disturbed by construction activities shall be seeded unless specifically shown on drawings to be sodded.

3. The types of seeding Work required include the following:

a. Seeding of berms and landscaped and other areas indicated, and areas disturbed during the construction process, except where other cover is called for.

b. Fertilizing.

c. Soil amendments.

d. Mulching.

e. Replant unsatisfactory or damaged turf.

f. Maintenance.

g. Guaranty.

B. Coordination:

Review installation procedures under other Sections and coordinate the installations of items that must be installed with the seeding.

1.2 REFERENCES

A. FS O-F-241 - Fertilizers, Mixed, Commercial.

1.3 DEFINITIONS

Weeds: Includes Dandelion, Jimsonweed, Quackgrass, Horsetail, Morning Glory, Rush Grass, Mustard, Lambsquarter, Chickweed, Cress, Crabgrass, Canadian Thistle, Nutgrass, Poison Oak, Blackberry, Tansy Ragwort, Bermuda Grass, Johnson Grass, Poison Ivy, Nut Sedge, Nimble Will, Bindweed, Bent Grass, Wild Garlic, Perennial Sorrel, and Brome Grass.

1.4 MAINTENANCE DATA


B. Submit maintenance instructions, cutting method and maximum grass height, types, application frequency, and recommended coverage of fertilizer.


A. Landscape Subcontractor Qualifications: Employ only experienced personnel who are familiar with the required Work. Provide adequate supervision by a qualified foreman.


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B. Provide seed mixture in containers showing percentage of seed mix, year of production, net weight, date of packaging, and location of packaging.


Comply with regulatory agencies for fertilizer and herbicide composition.


A. Deliver, store, protect and handle products to site under provisions of Section 01600.

B. Deliver grass seed mixture in sealed containers. Seed in damaged packaging is not acceptable.

C. Deliver fertilizer in waterproof bags showing weight, chemical analysis, and name of manufacturer.

1.8 MAINTENANCE SERVICE

A. In the absence of sufficient rain, seeded areas shall be watered a minimum of three times a week for not less than five weeks using Contractor's supplied water.

B. Maintain seeded areas for three months from Date of final payment.

1.9 JOB CONDITIONS

A. Environmental Requirements:

1. Proceed with and complete the seeding as rapidly as portions of the site become available, working within the seasonal limitations.

2. Do not spread seed when wind velocity exceeds 5 miles per hour.

B. Topsoil:

All grass areas disturbed during construction shall be restored with a four (4) inch layer of screened rich dark pulverized topsoil. Prior to the application of the final 4" of topsoil all excavations must be properly backfilled and compacted so as to minimize future settlement.

C. Scheduling:

Seed shall be applied only during normal planting seasons. Correlate seeding with specified maintenance periods.

1.10 GUARANTY

Guarantee seeding through the specified maintenance period, and for a period of one year from final payment.

PART 2 - PRODUCTS

2.1 SEED MIXTURE

A. Temporary

1. Foxtail Millet - 34 lb/ac.

B. Permanent

1. Green Sprangletop - 0.3 lb. PLS/ac.


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2. Sideoats Grama (Haskell) 4.5 PLS/ac.

3. Bermudagrass – 2.4 lb. PLS/ac.

2.2 SOIL MATERIALS

A. Topsoil.

1. Site topsoil: excavated and stockpiled on-site.

2. Borrowed topsoil: shall be friable loam, typical of cultivated topsoils of the locality, containing at least 4 percent of decayed organic matter (humus). It shall be taken from a well drained arable site. It shall be reasonably free of subsoil, stones, clods, sticks, roots and other objectionable extraneous matter or debris and shall meet the requirements of Off-Site Material as specified in Section 02317, Structural Excavation.

2.3 ACCESSORIES

A. Mulching Material: Oat or wheat straw, free from weeds, foreign matter detrimental to plant life, and dry.

B. Fertilizer: FS O-F-241, Type I, Grade A; recommended for grass, with fifty percent of the elements derived from organic sources. It shall contain a minimum of 5 percent Nitrogen, 10 percent Phosphorus and 5 percent Potash by weight.

C. Water: Clean, fresh and free of substances or matter which could inhibit vigorous growth of grass.

D. Erosion Fabric: Jute matting, open weave.

E. Stakes: Softwood lumber, chisel pointed.

F. String: Inorganic fiber.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Verify that building and trench backfilling have been inspected.

B. Verify substrate base has been contoured and compacted.

3.2 SUBSTRATE PREPARATION

A. Eliminate uneven areas and low spots.

B. Remove debris, roots, branches, stones, in excess of 1/2 inch in size. Remove subsoil contaminated with petroleum products.

C. Scarify subgrade to depth of 3 inches where topsoil is scheduled. Scarify areas where equipment was used for hauling and spreading topsoil and subsoil is compacted.

3.3 PLACING TOPSOIL

A. Spread topsoil to a minimum depth of 4 inches over area to be seeded. Rake until smooth.

B. Place topsoil in dry weather on dry unfrozen subgrade.


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C. Remove vegetable matter and foreign non-organic material from topsoil while spreading.

D. Grade topsoil to eliminate rough, low or soft areas, and to ensure positive drainage.

3.4 FERTILIZING

A. Apply fertilizer in accordance with manufacturer's instructions.

B. Apply after smooth raking of topsoil and prior to roller compaction.

C. Fertilizer shall not be applied at same time or with the same machine as will be used to apply seed.

D. Mix thoroughly into upper 2 inches of topsoil.

E. Lightly water to aid the dissipation of fertilizer.

3.5 SEEDING

A. Apply seed at rate indicated per acre evenly in two intersecting directions. Rake in lightly. Do not seed area in excess of that which can be mulched on same day.

B. Planting Season: Temporary season – May 1 through August 31; Permanent season – January 15 through May 1.

C. Do not sow immediately following rain, when ground is too dry, or during windy periods.

D. Roll seeded area with roller not exceeding 112 lbs.

E. Immediately following seeding and compacting, apply mulch to a thickness of 1/8 inches. Maintain clear of shrubs and trees.

F. Apply water with a fine spray immediately after each area has been mulched. Saturate to 4 inches of soil.

3.6 SEED PROTECTION

A. Identify seeded areas with stakes and string around area periphery. Set string height to 12 inches. Space stakes at 36 inches maximum.

B. Cover seeded slopes where grade is 3 inches per foot or greater with erosion fabric. Roll fabric onto slopes without stretching or pulling.

C. Lay fabric smoothly on surface, bury top end of each section in 6 inch deep excavated topsoil trench. Provide 12 inch overlap of adjacent rolls. Backfill trench and rake smooth, level with adjacent soil.

D. Secure outside edges and overlaps at 36 inch intervals with stakes.

E. Lightly dress slopes with topsoil to ensure close contact between fabric and soil.

F. At sides of ditches, lay fabric laps in direction of water flow. Lap ends and edges minimum 6 inches.

3.7 MAINTENANCE

A. Mow grass to maintain at a maximum height of 3 inches.

B. Neatly trim edges and hand clip where necessary.

C. Immediately remove clippings after mowing and trimming.


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D. Water to prevent grass and soil from drying out. In the absence of 1-inch rain per week, seeded and sodded areas shall be watered a minimum of three times a week for not less than five weeks.

E. Roll surface to remove minor depressions or irregularities.

F. Control growth of weeds. Apply herbicides in accordance with manufacturer's instructions. Remedy damage resulting from improper use of herbicides.

G. Immediately reseed areas which show bare spots.

H. Protect seeded areas with warning signs during maintenance period.

END OF SECTION


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BLANK PAGE


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SODDING 02922-1

SECTION 02937

SODDING

PART 1 - GENERAL


A. Restoration of existing lawn areas disturbed by construction shall be by installation of new sod.

B. Planting of sod within areas designated on Drawings for purpose of surface stabilization, channel stabilization or vegetation buffer strips.

C. Sod is defined as blocks, squares, strips of turfgrass, and adhering soil used for vegetative planting. To be placed edge to edge for complete coverage.

D. Lawn is defined as ground covered with fine textured grass kept neatly mowed.

1.2 SUBMITTALS



A. Sod only when weather and soil conditions are deemed by Owner’s Representative to be suitable for proper placement.

B. Water and fertilize new sod.

C. Guarantee sod to be growing 30 days after substantial completion.

D. Maintenance Period:

1. Begin maintenance immediately after each section of grass sod is installed and continue for 30 day period from date of substantial completion.

2. Resod unacceptable areas.

3. Water, fertilize, control disease and insect pests, mow, edge, replace unacceptable materials, and perform other procedures consistent with good horticultural practice to ensure normal, vigorous and healthy growth. Install disease control within guidelines set forth by Structural Pest Control Board of the State of Texas.

E. Notify Owner’s Representative 10 days before end of maintenance period for inspection.

PART 2 - PRODUCTS

2.1 SOD

A. Species: Bermuda (Cynodon Dactylon), Buffalo (Buchloe Dactyloides), or St. Augustine (Stenotaphrum Secundatum) Gulf Coast variety to match existing sod.

B. Contents: 95 percent permanent grass suitable to climate in which it is to be placed; not more than 5 percent weeds and undesirable grasses; good texture, free from obnoxious grasses, roots, stones and foreign materials.

C. Size: 12 inch wide strips, uniformly 2 inches thick with clean-cut edges.


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SODDING 02922-2

D. Sod is to be supplied and maintained in healthy condition as evidenced by grass being normal green color.

2.2 FERTILIZER

A. Available nutrient percentage by weight: 12 percent nitrogen, 4 percent phosphoric acid, and 8 percent potash; or 15 percent nitrogen, 5 percent phosphoric acid, and 10 percent potash.

2.3 WEED AND INSECT TREATMENT

A. Provide acceptable treatment to protect sod from weed and insect infestation. Submit treatment method to Owner’s Representative for approval. Install insect and disease control within guidelines set forth by Structural Pest Control Board of the State of Texas.

2.4 WATER

A. Potable, available on-site through Contractor's water trucks. Contractor may use City hydrants when water use is measured through Contractor's meter. Do not use private resident's water.

2.5 BANK SAND

A. Free of clay lumps, roots, grass, salt or other foreign material.

PART 3 - EXECUTION

3.1 PREPARATION

A. Verify that soil placement and compaction have been satisfactorily completed. Verify that soil is within allowable range of moisture content.

B. Top soil shall be free of weeds and foreign material immediately before sodding.

C. Do not start work until conditions are satisfactory. Do not start work during inclement or impending inclement weather.

D. Rake areas to be sodded smooth, free from unsightly variations, bumps, ridges or depressions.

E. Spread 2 inch layer of bank sand over areas to be sodded prior to planting of sod.

F. Apply fertilizer at rate of 25 pounds per 1000 square feet. Apply after raking soil surface and not more than 48 hours prior to laying sod. Mix thoroughly into upper 2 inches of soil. Lightly water to aid in dissipation of fertilizer.

3.2 APPLICATION

A. Full Sodding: Lay sod with closely fitted joints leaving no voids and with ends of sod strips staggered. Lay sod within 24 hours of harvesting.

B. On slopes 2:1 and steeper, lay sod perpendicular to slope and secure every row with wooden pegs at maximum 2 feet on center. Drive pegs flush with soil portion of sod.


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SODDING 02922-3

C. Prior to placing sod, on slopes 3:1 or where indicated, place Hold/Gro or Roll Lite or equal over topsoil. Securely anchor in place with posts sunk firmly into ground at maximum 16 feet on center along pitch of slope and equal to width of wire mesh horizontally across slopes.

D. After sod is laid, irrigate thoroughly to secure 6-inch minimum penetration into soil below sod.

E. Tamp and roll sod with approved equipment to eliminate minor irregularities and to form close contact with soil bed immediately after planting and watering. Submit type of tamping and rolling equipment to be used to Owner’s Representative for approval, prior to construction.

3.3 MAINTENANCE

A. Watering:

1. Water lawn areas once a day with minimum 1/2 inch water for first 3 weeks after area is sodded.

2. After 3 week period, water twice a week with 3/4 inch of water each time unless comparable amount has been provided by rain.

3. Make weekly inspections to determine moisture content of soil unless soil is in frozen condition.

4. Water in afternoon or at night to enable soil to absorb maximum amount of water with minimum evaporation.

B. Mowing:

1. Mow sod at intervals which will keep grass height from exceeding 3 1/2 inches.

2. Set mower blades at 2 1/2 inches.

3. Do not remove more than one-half of grass leaf surface.

4. Mow sodded areas requiring mowing within 1 month after installation with light-weight rotary type mower. Mow sod only when dry and not in saturated or soft condition.

5. Remove grass clippings during or immediately after mowing.

C. Fertilizer and Pest Control:

1. Evenly spread fertilizer composite at rate of 40 pounds per 5000 square feet or as recommended by manufacturer. Do not place fertilizer until 2 weeks after placement of sod.

2. Restore bare or thin areas by topdressing with mix of 50 percent sharp sand and 50 percent sphagnum peat moss.

3. Apply mixture 1/4 to 1/2 inch thick.

4. Treat areas of heavy weed and insect infestation as recommended by treatment manufacturer.


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SODDING 02922-4

D. Restrict all traffic from sodded areas until sod is established or for minimum 10 days during growing season. Use wood lath and plastic tape to cordon sodded areas. Maintain tape and lath throughout for minimum 30 days during growing season.

3.4 CLEANUP

A. During course of planting, remove excess and waste materials; keep lawn areas clean and take precautions to avoid damage to existing structures, plants, grass, and streets.

B. Remove barriers, signs, and other Contractor material and equipment from project site at termination of establishment period.

C. Dispose of unused materials and rubbish in accordance with Section 01750 - Waste Material Disposal.

END OF SECTION


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CONCRETE FORMWORK 03110-1

SECTION 03110

CONCRETE FORMWORK

PART 1 - GENERAL

Not used.

PART 2 - PRODUCTS

2.1 MATERIAL

A. Smooth Forms.

1. Construct formwork with plywood; tempered, concrete-form hard board; dressed lumber faced with plywood or fiberboard lining; metal; plastic; or metal-framed plywood-faced panel material to provide continuous, straight smooth surfaces. Form material shall be free of raised grain, torn surfaces, worn edges, patches, dents or other defects. Furnish material in largest practical sizes to minimize the number of joints and, when shown on the drawings, conform to the joint system shown. Form material shall have sufficient strength and thickness to withstand the pressure of newly placed concrete without bow or deflection.

2. Smooth forms shall be used on all formed concrete surfaces specified to have a smooth form finish in Section 03360 – Concrete Finishing.

B. Rough Forms.

1. Construct forms of dressed or undressed lumber free of knots, splits or other defects; plywood; metal; or other material acceptable to the Engineer. Material shall have sufficient strength and thickness to withstand the pressure of newly placed concrete without bow or deflection.

2. Rough forms may be used on all formed concrete surfaces specified as rough form finish in Section 03360 – Concrete Finishing.

C. Shores. Wood or adjustable metal type with bearing plates and with double wedges at the bottom.

D. Form Ties. Factory fabricated, adjustable length, removable or snap-off metal ties, designed to prevent form deflection and to prevent spalling concrete surfaces upon removal. Provide ties so that the portion remaining within concrete is at least 1-1/2 inches from the outer surfaces. Form ties shall be provided with a water seal feature in liquid-containing structures.

E. Form Coating. Use commercial formulation of form oil or form-release agent having proven satisfactory performance. Coating must not bond with, stain or adversely affect concrete surfaces. It must not impair subsequent treatment of concrete surfaces, including bonding agents and curing compounds.

F. Coating for Plastic Forms. Alkali-resistant gel-coat.

G. Chamfer Strips. Provide in corners of forms to produce beveled edges at specified locations. Size of chamfer is 3/4 inch unless shown otherwise.

2.2 DESIGN OF FORMWORK

A. Form Design. The design and engineering of all concrete formwork, including all shoring and bracing, shall be the responsibility of the Contractor. Design formwork for applicable gravity loads, lateral pressure, wind loads, soil compaction equipment surcharge loads and allowable stresses. Conform to the requirements of controlling local building codes.


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Camber formwork to compensate for anticipated deflection during placement of concrete when required to maintain specified tolerances. Design formwork to be readily removed without impact, shock or damage to concrete surfaces and adjacent materials.

B. Slip Forming. Not permitted.

PART 3 - EXECUTION

3.1 FORMWORK CONSTRUCTION

A. General.

1. Construct and maintain formwork so that it will maintain correct sizes of members, shape, alignment, elevation and position during concrete placement and until concrete has gained sufficient strength. Provide for required openings, offsets, keyways, recesses, moldings, anchorages and inserts.

2. Construct forms for easy removal without damage to concrete surfaces.

3. Formwork shall be sufficiently tight to prevent leakage of cement paste during concrete placement. Solidly butt joints and provide backup material at joints as required to prevent leakage and fins.

4. Chamfer strips shall be placed in forms to bevel all edges and corners permanently exposed to view. Edges of formed joints and interior corners shall not be beveled unless shown or specified otherwise. Equipment bases shall have formed beveled edges for all vertical and horizontal corners. Unless otherwise noted, bevels shall be 3/4 inch wide.

5. Provide temporary openings at the base of wall forms and at other points as required to facilitate observation and cleaning immediately before concrete is placed.

6. If runways are required for moving equipment, support runways on the formwork or structural member. Do not allow runways or supports to rest on reinforcing steel.

7. Contractor shall not commence backfilling operations against exterior walls until concrete has reached full specified strength.

B. Forms for Surfaces Requiring Smooth Form Finish.

1. Drill forms to suit ties used and to prevent leakage of concrete mortar around tie holes. Form ties shall be uniformly spaced and aligned in horizontal and vertical rows.

2. Provide sharp, clean corners at intersecting planes, without visible edges or offsets. Back joints with extra studs or girts to maintain true, square intersections.

3. Form molding shapes, recesses and projections with smooth-finish materials and install in forms with sealed joints to prevent displacement.

4. Provide all exterior exposed edges with 3/4-inch chamfer.

5. Arrange facing material in an orderly and symmetrical fashion. Keep the number of joints to a practical minimum. Support facing material adequately to prevent deflection in excess of allowable tolerances.


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6. For flush surfaces exposed to view in the completed structure, overlap previously placed, hardened concrete with form sheathing by approximately 1 inch. Hold forms against hardened concrete to maintain true surfaces, preventing offsets or loss of mortar.

C. Edge Forms and Screed Strips for Slabs. Set edge forms or bulkheads and intermediate screed strips for slabs to obtain required elevations and contours in the finish slab surface. Provide and secure supports for types of screeds required.

D. Tolerances.

1. Construct formwork so that concrete surfaces will conform to tolerance limits as listed in Table 3A at the end of this section unless noted otherwise on the drawings.

2. Establish sufficient control points and bench marks as references for tolerance checks. Maintain these references in undisturbed condition until final completion and acceptance of the project.

3. To maintain the specified tolerances, the formwork shall be cambered to compensate for anticipated deflections, in the formwork, due to weight of the wet concrete.

E. Adjustments of Formwork.

1. Use wedges or jacks to provide positive adjustment of shores and struts. Wedges used for final adjustment of forms shall be fastened in position after final inspection and before concrete placement.

2. Securely brace forms against lateral deflections. Prepare to compensate for settling during concrete placement.

3. For wall openings, construct wood forms that facilitate any necessary loosening to counteract swelling of forms.

3.2 PREPARATION OF FORM SURFACES

A. Before placing concrete, clean surfaces of forms and embedded materials. Remove accumulated mortar, grout, rust and other foreign matter.

B. Coat forms with form oil or form-release agent before placing reinforcement. Cover form surfaces with coating material used in strict accordance with the manufacturer's printed instructions. Do not allow excess coating material to accumulate in forms or to contact hardened concrete against which fresh concrete will be placed. Remove coating material from reinforcement before placing concrete.

C. Other than retained-in-place metal forms, forms for unexposed surfaces may be wet with water immediately before concrete placement in lieu of coating. One exception is that when a possibility of freezing temperatures exists, use of a coating is mandatory.

3.3 REMOVAL OF FORMS

A. General.

1. When repair of surface defects or finishing is required before concrete is aged, forms on vertical surfaces may be removed as soon as concrete has hardened sufficiently to resist damage from removal operations.

2. All forms and shoring used to support weight of concrete or any construction loads shall remain in place until concrete has reached the minimum strength specified for removal of forms and shoring. In no case shall forms be removed in less than 4 days.


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B. Removal Strength.

1. Control Tests. Suitable strength control tests will be required as evidence that concrete has attained specified strength for removal of formwork or shoring supporting weight of concrete in beams, slabs and other structural members. Test cylinders and test data to verify strength for early form removal shall be furnished by the Contractor.

a. Field-Cured Test Cylinders. When field-cured test cylinders reach the specified removal strength, formwork or shoring may be removed from the respective concrete placements.

b. Laboratory-Cured Test Cylinders. When concrete has been cured as specified for cast-in-place concrete for the same time period required by laboratory-cured cylinders to reach specified strength, the formwork or shoring may be removed from respective concrete placements. Determine the length of time that the concrete placement has been cured by totaling the number of days or fraction of days, not necessarily consecutive, during which the air temperature surrounding the concrete is above 50 F and the concrete has been damp or thoroughly sealed against evaporation and loss of moisture.

2. Compressive Strengths. The minimum concrete compressive strengths for removal of all formwork supporting the weight of concrete shall be 75 percent of the specified minimum 28-day strength of the class of concrete involved.

3.4 FORM REUSE

Do not reuse forms that are worn or damaged beyond repair. Thoroughly clean and recoat forms before reuse. For wood and plywood forms to be used for exposed smooth finish, sand or otherwise dress concrete contact surface to original condition or provide form liner facing material. For metal forms, straighten, remove dents and clean to return to original condition.


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TABLE 3A

TOLERANCES FOR FORMED SURFACES

CONCRETE IN BUILDINGS,

CONCRETE IN WATER TREATMENT STRUCTURES AND

CONCRETE IN WASTEWATER TREATMENT STRUCTURES

VARIATION

FROM VARIATION IN

FOR ANY

10 FOOT

LENGTH

FOR ANY

20 FOOT

LENGTH OR

ANY BAY

MAXIMUM

FOR ENTIRE

DIMENSION

PLUMB OR

SPECIFIED

BATTER

LINES AND SURFACES OF COLUMNS, PIERS, WALLS AND ARRISES 1/4" C 1"

EXPOSED CORNER COLUMNS, CONTROL JOINT GROOVES, AND OTHER CONSPICUOUS LINES

C 1/4" 1/2"

LEVEL OR

SPECIFIED

GRADE

SLAB SOFFITS, CEILINGS, BEAM SOFFITS, AND IN ARRISES (MEASURED BEFORE REMOVAL OF SHORES)

1/4" 3/8" 3/4"

EXPOSED LINTELS, SILLS, PARAPETS HORIZONTAL GROOVES AND OTHER CONSPICUOUS LINES

C 1/4" 1/2"

DRAWING

DIMENSIONS

POSITION OF LINEAR BUILDING LINES, COLUMNS, WALLS, AND PARTITIONS

C 1/2" 1"

SIZE AND LOCATION OF SLEEVES, FLOOR OPENINGS AND WALL OPENINGS

C C +1/4"


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CROSS SECTION OF COLUMNS, BEAMS, SLABS, AND WALLS

C C +1/2", -1/4"

FOOTINGS* IN PLAN C C +2", -1/2"

FOOTING MISPLACEMENT OR ECCENTRICITY IN DIRECTION OF ERROR (THE LESS OF)

C 2% OF WIDTH

OR 2"

FOOTING THICKNESS DECREASE

C C 5%

FOOTING THICKNESS INCREASE

C C NO LIMIT

STEP RISE IN FLIGHT OF STAIRS

C C +1/8"

STEP TREAD IN FLIGHT OF STAIRS

C C +1/4"

CONSECUTIVE STEP RISE C C +1/16"

CONSECUTIVE STEP TREAD C C +1/8"

* Footing tolerances apply to concrete dimensions only, not to positioning of vertical reinforcing steel,

dowels, or embedded items.

END OF SECTION


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CONCRETE JOINTS AND EMBEDDED ITEMS 03150-1

SECTION 03150

CONCRETE JOINTS AND EMBEDDED ITEMS

PART 1 - GENERAL

1.1 SUBMITTALS

A. Product Data.

1. When substitutions are proposed by the Contractor as equal to brands of materials specified herein, submit brochures and samples of proposed substitutions for approval before delivery to the project.

2. Submit manufacturer's technical literature on product brands, proposed for use by the Contractor. The submittal shall include the manufacturer's installation and/or application instruction. Submittals shall be made on the following products:

a. Bonding agent.

b. Hydrophilic waterstop.

PART 2 - PRODUCTS

2.1 CONCRETE BONDING AGENTS

A. Epoxy Bonding Agent. Shall permanently bond fresh wet concrete to cured concrete and shall conform to ASTM C 881, Type II. Bonding agent shall develop the full strength of the concrete. Grade and class shall be as required for the project application. A field service representative of the manufacturer shall be present during initial application to instruct the Contractor in the proper use of the product when so requested by the Engineer or the Contractor.

B. Latex Bonding Agent. Non-remulsifiable latex base liquid formulated for bonding wet concrete to hardened concrete and for mixing with cement mortar. Bonding agent shall be certified by the manufacturer for use in a continuously submerged environment. Acceptable product is SBR Latex by the Euclid Chemical Company or approved equal.

2.2 SLEEVES

Rigid PVC pipe.

2.3 WATERSTOPS

See plans for location and type required.

A. Hydrophilic Expansion Rubber Waterstop/Seal. Where shown on the Drawings, provide a waterstop/seal of a compound of hydro-swelling resin and chloroprene rubber of high resilience. The hydrophilic waterstop shall swell upon contact with water.

1. Waterstop. Where indicated in concrete construction, use a waterstop consisting of hydrophilic expansion rubber and butyl rubber. Minimum swelling ratio shall be 1.7 times the original volume.

2. Seal. Where indicated for precast elements, use a seal composed of hydrophilic expansion rubber with a minimum swelling ratio of two times the original volume.

2.4 MISCELLANEOUS EMBEDDED METAL ITEMS

Miscellaneous embedded metal items shall conform to the requirements of the section of the specifications to which they apply.


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PART 3 - EXECUTION

3.1 GENERAL

A. Place embedded items to least impair strength of the structure. Obtain approval of locations for embedded items not shown on the structural drawings before placement of concrete. Should locations of embedded items be detrimental to the strength of the structure, notify the Engineer and relocate items as directed by the Engineer.

B. Do not cut or reposition reinforcing steel to facilitate installation of inserts, conduit, sleeves, anchor bolts, mechanical openings and similar items without prior approval of the Engineer, except that reinforcing bars may be moved one bar diameter or within tolerances specified in Section 03210 – Concrete Reinforcement without prior approval.

3.2 CONSTRUCTION JOINTS

A. All joints shall be perpendicular to main reinforcement. Continue all reinforcing steel across construction joints. Unless otherwise shown, provide longitudinal keys at least 1-1/2 inches deep by one third of the wall thickness, centered in the wall, in all joints in walls.

B. Prepare joints by roughening the concrete surface in a manner which will expose aggregate uniformly. Remove laitance, loosened particles of aggregate, damaged concrete at surface, and other substances which may prevent complete adhesion. Prior to placing concrete, coat the joint surface with a mixture of neat cement grout.

C. In lieu of the above method for securing bond between new and set concrete, the following optional method may be used. Use a latex bonding agent as specified applied to roughened and cleaned surfaces of set concrete in strict accordance with manufacturer's recommendations and these specifications with respect to preparation of surfaces and applications of bond agent.

D. Provide waterstops in all wall and slab construction joints as specified or where shown on the drawings.

3.3 EPOXY BONDED JOINTS

Epoxy bonded joints shall be used only where shown on the drawings, where specified, or upon written approval of the Engineer. Prepare surface to be bonded and apply bonding agent in strict accordance with the manufacturer's instructions and ACI 503.2, except that surface preparation by acid etching will not be allowed. When ACI 503.2 references ACI 301, delete ACI 301 and substitute the project specifications' Cast-in-Place Concrete section. Forms in the area of the bonded joint shall be properly protected so that any bonding agent that may be inadvertently applied to the form will not bond the form to the concrete.

3.4 WATERSTOPS

A. Provide waterstops in all horizontal and vertical joints in foundation slabs and peripheral walls of all structures up to a minimum of 12 inches above final ground level and all walls and slabs of liquid-containing structures or compartments to a minimum of 12 inches above maximum liquid level unless specifically shown otherwise on the drawings. In addition, provide waterstops in joints of interior walls of liquid containing structures when shown on the drawings.

B. Waterstops shall be hydrophilic waterstops.

C. Each piece of waterstop shall be of maximum practicable length for a minimal number of end joints.


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D. Joint surface must be clean and dry. Butt ends of waterstop together (do not overlap). Any material that exhibits swelling prior to confinement in the joint must be replaced with new material. Waterstop shall be placed with an epoxy adhesive to the first pour. Secure the waterstop during second pour for horizontal placements by providing a groove for the waterstop; and for vertical placement, secure the waterstop with concrete nails at 12 inches on center.

E. Accurately position and support waterstops against displacement during concrete placement.

3.5 SEALING JOINTS

A. Apply sealant at all expansion and isolation joints in slabs on grade and at other locations as shown on the drawings.

B. Do not apply sealants until all curing shrinkage has taken place.

C. Thoroughly clean and prime joints to be sealed before applying sealant. Joints to be sealed are identified on the drawings.

D. Apply sealants in accordance with manufacturer's recommendations.

E. Sealant shall be applied when the ambient temperature is between 40 F and 90 F, unless recommended otherwise by the sealant manufacturer.

F. During pouring operations, exercise care to prevent sealant from spilling onto surfaces adjacent to grooves.

3.6 SETTING ANCHOR BOLTS

A. Set anchor bolts specified in other sections according to this section.

B. Install equipment anchor bolts as required by the equipment manufacturer.

C. Provide accurately made templates for positioning anchor bolts.

3.7 OTHER EMBEDDED ITEMS

A. It is the Contractor's responsibility to coordinate the requirements for embedded items and to ensure that embedded items are properly placed.

B. Accurately position and support embedded items against displacement during concrete placement.

C. Voids in sleeves, inserts, anchors, etc., shall be filled temporarily with readily removable material to prevent the entry of concrete into the voids.

D. Steel items, except reinforcing, shall be galvanized unless specified or shown otherwise. Galvanized embedded items shall not be in contact with the reinforcing steel or ungalvanized steel items.

E. Conduits, pipes and inserts of aluminum shall not be embedded in structural concrete unless effectively coated or covered to prevent aluminum-concrete reaction or electrolytic action between aluminum and steel.

F. Except when plans for conduits and pipes are approved by the Engineer, conduits and pipes embedded within a slab, wall or beam (other than those merely passing through) shall satisfy the following:

1. They shall not be larger in outside dimension than 1/3 the overall thickness of slab, wall or beam in which they are embedded.

2. They shall not be spaced closer than three diameters or widths on center.

3. They shall not significantly impair the strength of the member.


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END OF SECTION

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CONCRETE REINFORCEMENT 03210-1

SECTION 03210

CONCRETE REINFORCEMENT

PART 1 - GENERAL

1.1 HANDLING AND STORAGE

Store steel reinforcement above the ground on platforms, skids or other supports. Protect reinforcing, as far as practicable, from mechanical injury, surface deterioration and rusting caused by exposure to the weather.


Notify the Engineer at least 48 hours before concrete placement so that reinforcement may be inspected and errors corrected without delaying the work.

PART 2 - PRODUCTS

2.1 MATERIAL

A. Reinforcing Bars. Deformed bars conforming to ASTM A 615 including Supplementary Requirements SI, grade as shown on the drawings, for all bars except those shown on drawings to be smooth bars. Where grade is not shown on the drawings, use Grade 60; No. 3 bars may be Grade 40.

B. Tie Wire. Use 16-1/2-gauge or heavier annealed steel for tie wire.

C. Bar Supports. Provide chairs, riser bars, ties and other accessories made of plastic or metal, except as otherwise specified. Bar supports and accessories shall be of the sizes required to provide concrete cover as specified. Where concrete surfaces are exposed to the weather or liquid in liquid-containing structures in finished work, provide plastic accessories only. Use of galvanized or plastic-tipped metal is not permitted in these locations. Metal bar supports and accessories shall be Class 1 or 2 conforming to the requirements of CRSI Manual of Standard Practice.

D. Epoxy Grout. Epoxy grout shall be a high-strength rigid epoxy adhesive manufactured for the purpose of anchoring dowels into hardened concrete. The epoxy grout shall be capable of developing the full strength of the reinforcing bar.

2.2 FABRICATION

A. Bending. Fabricate bars to the shapes shown on the drawings by cold bending. Bends shall conform to the minimum bend diameters specified in ACI 318. Do not straighten or rebend bars without specific approval.

B. Splices. Locate splices as shown on the drawings. Where it is necessary to splice reinforcement at locations other than shown on the drawings, the splices shall be approved by the Engineer. Use a minimum number of splices located at points of minimum stress. Stagger splices in adjacent bars.

C. Construction Joints. Reinforcing shall be continuous through construction joints.

D. Fabrication Tolerances. Conform to the fabrication tolerances shown in ACI 315.

E. Marking. Clearly mark all bars with waterproof tags showing the number of bars, size, mark, length and yield strength. Mark steel with the same designation as the member in which it occurs.


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CONCRETE REINFORCEMENT 03210-2

PART 3 - EXECUTION

3.1 PREPARATION

Clean reinforcement of all scale, loose or flaky rust or other foreign material, including oil, mud or coating that will reduce the bond to concrete.

3.2 INSTALLATION

A. Placement Tolerances. Place reinforcement as shown on the drawing or per ACI 318.

B. Placement in Forms. Use spacers, chairs, wire ties and other accessory items necessary to properly assemble, space and support reinforcing. Provide accessories of sufficient number, size and strength to adequately prevent deflection or displacement of reinforcement due to construction loads or concrete placement. Use appropriate accessories to position and support bolts, anchors and other embedded items. Tie reinforcing bars at each intersection and to accessories. Blocking reinforcement with concrete or masonry is prohibited.

C. Splices.

1. Do not splice bars, except at locations shown on the drawings or the reviewed shop drawings, without approval of the Engineer.

2. Lap Splices. Tie securely with wire to prevent displacement of splices during placement of concrete.

D. Construction Joints. Place reinforcing continuous through construction joints.

E. Field Bending. Shape reinforcing bent during construction operations to conform to the drawings. Bars shall be cold-bent; do not heat bars. Closely inspect the reinforcing for breaks. If reinforcing is damaged, replace, Cadweld or otherwise repair as directed by the Engineer. Do not bend reinforcement after it is embedded in concrete.

F. Field Cutting. Reinforcing bars cut on the job shall be cut by shearing or sawing. Do not cut bars with a cutting torch unless approved by the Engineer.

G. Welding. Welding of reinforcing bars is prohibited.

3.3 GROUTING OF REINFORCING BARS

Use specified epoxy grout for anchoring reinforcing steel to existing concrete. Drill hole in existing concrete that is 1/4 inch to 1/2 inch larger than the diameter of the reinforcing bar. Holes drilled with air tools that blow out the dust while drilling shall be blown clean of all debris with compressed air, from the bottom up, immediately prior to installation of the reinforcing bar. Holes drilled with other type of equipment shall be reamed with a stiff wire brush on the end of a drill. Immediately prior to installation of the reinforcing bar, blow the hole clean from the bottom up of all debris using compressed air. Partially fill the hole with epoxy from the bottom up. Use enough epoxy so that when the bar is inserted, the epoxy grout will completely fill the hole around the dowel. Dip the end of the reinforcing bar in epoxy and install into the partially filled hole. Follow manufacturer's instructions in use of epoxy.

END OF SECTION


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INCIDENTAL CONCRETE 03305-1

SECTION 03305

INCIDENTAL CONCRETE

PART 1 - GENERAL

1.1 SUMMARY

Provide concrete, reinforcement and formwork for incidental uses such as housekeeping pads and pier foundations.

1.2 DESIGN CRITERIA

Concrete construction shall conform to the “Building Code Requirements for Reinforced Concrete,” ACI 318.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Formwork.

Dressed lumber, plywood, steel or prefabricated form with sufficient strength and backing to withstand the pressure of newly placed concrete without bowing or distortion.

B. Reinforcing.

1. Deformed bars conforming with ASTM A 615, including Supplementary Requirement S1, Grade 60.

2. Use 16-1/2 gauge or heavier annealed steel tie wire.

3. Provide a minimum of 2 inches of concrete cover for reinforcing in liquid containing concrete structures. See plans for minimum concrete cover requirements for other conditions.

C. Concrete.

1. Cement shall be ASTM C 150, Type I, gray.

2. Water shall be fresh, clean and potable.

3. Coarse aggregate shall consist of gravel, crushed stone or crushed limestone conforming to ASTM C 33.

4. Fine aggregate shall be natural sand complying with grading and requirements of ASTM C 33.

5. Mix design shall be Class A, 3000 psi concrete, measured, mixed and transported according to ASTM C 94.

D. Anchor Bolts.

ASTM A 307, Grade A, with Class 50 galvanizing.

PART 3 - EXECUTION

3.1 PREPARATION

Substrate shall be clean, dry and free of extraneous substances. Surface of slabs to receive pads shall be rough (float finish). If installing pads over a hard troweled surface, use bonding agent or mechanically roughen surface to achieve bond.


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INCIDENTAL CONCRETE 03305-2

3.2 FORMWORK

Erect square and true to line. Use minimum 3/4-inch chamfer strips for vertical edges. Coordinate placement of anchor bolts.

3.3 REINFORCING

Place bars or welded wire fabric at midpoint of slab. Bars shall not be spliced.

3.4 CONCRETE

Observe ACI standards for cold and hot weather concreting, and for concrete placement.

END OF SECTION


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CAST-IN-PLACE CONCRETE 03310-1

SECTION 03310

CAST-IN-PLACE CONCRETE

PART 1 - GENERAL

1.1 SUBMITTALS

A. Design Mixes.

1. Submit test data on proposed design mix including each strength class and any variations in either fly ash source and quantity, admixture, aggregate source or maximum coarse aggregate size.

2. Submittals shall include type and brand of cement used; mix design proportions; brand, type and amount of each admixture; brand and amount of fly ash; slump; amount of entrained air; aggregate sources, gradations, specific gravity and coarse aggregate dry rodded unit weight; total water (including moisture in aggregate); water/cement ratio; and compressive strength test results for 7 and 28 days.

3. For limestone aggregate submit abrasion loss and soundness test results.

4. All testing of aggregates including sieve analysis, shall be performed by a certified independent testing laboratory. Tests shall have been performed no earlier than 3 months before the notice to proceed date.

5. Review and acceptance of the mix design does not relieve the Contractor of his responsibility to provide concrete of the quality and strength required by the specifications.

B. Admixtures. Acceptable brands of admixtures are listed herein. If proposed products are different from those listed, submit manufacturer's technical information, including the following information, for review.

1. Submit evidence that the proposed admixture is equal to the listed acceptable brands.

2. Air-Entraining Admixture. Give requirements to control percent of air content under all conditions, including temperature variations and presence of other admixtures.

3. Chemical Admixtures. Give requirements for quantities and types to be used under various temperatures and job conditions to produce a uniform, workable concrete mix. Submit evidence of compatibility with other admixtures proposed for use in the design mix.

4. Submit evidence that the admixtures proposed for use with cement containing fly ash are compatible with the fly ash.

5. Submit evidence that admixtures proposed for use along with a superplasticizer are compatible with the proposed superplasticizer.


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C. Water Reducer (Superplasticizer). When a superplasticizer is proposed for use on the project, submit manufacturer's technical information and instructions for use of the superplasticizer proposed for use. State whether superplasticizer will be added at the ready-mix plant or the job site. When superplasticizer will be added at the job site submit proposed plan for measuring and adding superplasticizer to the concrete mix at the job site. Establish a dosing area on site with holding tanks and metering devices. If superplasticizer is to be added at the ready-mix plant submit contingency plans for adding additional superplasticizer at the job site if and when required due to delay in placing concrete. Identify the portions of the project on which superplasticizer is proposed for use.

D. Limestone Aggregate. Submit test data confirming that the limestone aggregate proposed for use on this project conforms to these specifications.

E. Curing Method. Submit the proposed curing method for all concrete.

F. Curing and Sealing Compound. Submit manufacturer’s technical information for proposed curing and sealing compound. Submittal shall include the specified testing laboratory test data.

G. Hot and Cold Weather Concreting. Submit, when applicable, proposed plans for hot and cold weather concreting. Review and acceptance of the proposed procedure will not relieve the Contractor of responsibility for the quality of the finished product.

1.2 STORAGE OF MATERIALS

A. Cement. Store cement in weathertight buildings, bins or silos to provide protection from dampness and contamination and to minimize warehouse set.

B. Aggregate. Arrange and use aggregate stockpiles to avoid excessive segregation or contamination with other materials or with other sizes of like aggregates. Build stockpiles in successive horizontal layers not exceeding 3 feet in thickness. Complete each layer before the next is started. Do not stockpile coarse aggregate in a cone.

C. Fine Aggregate. Before using, allow fine aggregate to drain until a uniform moisture content is reached.

D. Admixtures. Store admixtures to avoid contamination, evaporation or damage. For those used in the form of suspensions or nonstable solutions, provide suitable agitating equipment to assure uniform distribution of ingredients. Protect liquid admixtures from freezing and other temperature changes which would adversely affect their characteristics.

1.3 CODE REQUIREMENTS

Concrete construction for buildings shall conform to the requirements of ACI 318. Concrete construction for wastewater treatment structures shall conform to the requirements of ACI 318 with modifications as per ACI 350R, item 2.6, “Structural Design.” Where the project specifications conflict with ACI 318 or ACI 350R, the project specifications shall control.

1.4 TESTING

A. The concrete testing required in this section, except for the concrete mix design, the limestone aggregate test data, and testing of deficient concrete, will be performed by a commercial testing laboratory employed and paid by the Owner as specified in the General Conditions and Section 01380 – Quality Control.

B. Provide material and cooperate fully with Owner's testing laboratory technician in obtaining samples for required tests.


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Provide the necessary controls during evaluation of materials, mix designs, production and delivery of concrete, placement, compaction, finishing and curing necessary to assure that the work will be accomplished in accordance with the contract documents.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Cement. Gray Portland cements conforming to ASTM C 150, Type I or Type II. Type III may be used only when specifically authorized by the Architect/Engineer in writing.

B. Admixtures. Use the following admixtures as required. The use of calcium chloride, thiocyanates or admixtures containing more than 0.05 percent chloride ions are not permitted.

1. Air-Entraining Admixtures. Conform to ASTM C 260, liquid vinsol resin compound compatible with any chemical admixtures used. Acceptable products are Master Builders’ “MB-VR,” Sika’s “AER,” Euclid Chemical Company’s “Air-Mix,” W. R. Grace’s “Daravair” or approved substitution.

2. Chemical Admixtures. Conform to ASTM C 494, Type A, C, D or E. The admixture shall be a polymer type, nonstaining, chloride-free admixture. Acceptable products are Master Builders’ “Pozzolith,” Euclid Chemical Company’s “Accelguard” and “Eucon,” or approved substitution.

C. Mixing Water. Use fresh, clean potable water.

D. Aggregates. Use coarse aggregate from only one source and fine aggregate from only one source for exposed concrete in a single structure.

1. Coarse aggregate for concrete of normal weight shall consist of gravel, crushed gravel or crushed limestone conforming to ASTM C 33.

2. Fine aggregate shall be natural sand complying with ASTM C 33.

3. Limestone aggregate shall conform to the requirements of ASTM C 33 with the following additional requirements: Limestone aggregate shall consist of clean, hard, strong and durable particles free of chemicals, coatings of silt or clay, or other fine materials that may affect hydration and bond of the cement paste. The select crushed limestone shall be high-calcium limestone (minimum 95 percent CaCO3 and maximum 3.5 percent MgCO3) with maximum Los Angeles Abrasion loss of 38 percent; when tested in accordance with ASTM C 131 or ASTM C 535. The aggregate shall be tested for soundness in accordance with ASTM C 88. The maximum loss shall not exceed 18 percent after 5 cycles of the magnesium sulfate test.

4. The maximum size of coarse aggregate shall be as follows:

a. Normal weight concrete – 1 inch – (ASTM C 33, size No. 57)

b. Formed members 9 inches or less in least dimension - 3/4 inch maximum (ASTM C 33, size No. 67).

c. Slabs 9 inches or less in depth - 3/4 inch maximum (ASTM C 33, size No. 67).

d. Drilled shaft - 3/4 inch maximum (ASTM C 33, size No. 67).

e. Lightweight concrete shall conform to ASTM C 330. Grading limits are 3/4 inch to No. 4.


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E. Nonshrink Grout. Corps of Engineers CRD-621-80, pre-mixed, factory packaged, nonmetallic aggregate mortar grouting compound, such as Euclid “High-Flow” nonshrink grout or Master Builders “Masterflow 713,” or approved substitution.

F. Calcium Chloride. Not permitted in any form.

G. Fly Ash.

1. Fly ash shall conform to the requirements of ASTM C 618.

2. Fly ash shall be produced from coal from a single known and consistent source.

2.2 CONCRETE MIX

A. Objective. Select proportions of ingredients to produce a concrete having proper placeability, durability, strength, appearance and other specified properties. Minimum cement content shall conform to these specifications. Proportion ingredients to produce a homogeneous mixture which will work readily into corners and angles of forms and around reinforcement by methods of placing and consolidation employed on the project, but without permitting materials to segregate or allowing excess free water to collect on the surface.

B. Mix Design. The Contractor shall employ, at his expense, a commercial testing laboratory, acceptable to the Owner, to prepare and test mix designs for each type of concrete specified herein. The mix design ingredients shall be proportioned by weight. The mix design and test results shall be submitted for review. See Article 1.4, Submittals, for required data.

C. Compressive Strength.

1. Concrete for drilled piers shall have a 4000 psi concrete strength at 28-days.

2. All structural concrete shall be normal weight concrete and weigh not more than 150 pcf and shall have a 4500 psi concrete strength at 28-days. Structural concrete shall have a 7-day compressive strength of 3100 psi.

3. All light weight concrete for composite roof deck shall weigh not more than 110 pcf and shall have a 4000 psi concrete strength at 28-days.

D. Superplasticizer may be added as specified to obtain maximum water-cement ratios. Include free water in the aggregate in all water-cement ratio computations. When fly ash is substituted

E. Fly Ash. Fly ash may be substituted for part of the cement. If fly ash is used in the proposed concrete mix, the percent of fly ash by weight in the combined fly ash cement mixture shall not exceed 27 percent.

F. Water-Cement Ratio.

1. The maximum allowable water-cement ratio shall not exceed 0.45.

2. Superplasticizer may be added as specified to obtain maximum water-cement ratios. Include free water in the aggregate in all water-cement ratio computations. When fly ash is substituted for part of the cement, the weight of the cement plus fly ash shall be used in calculating the water-cement ratio.

G. Entrained Air.

1. Air-entrain all concrete 5% ± 1% unless otherwise specified.


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H. Slump. Slump as determined in accordance with ASTM C 143 shall be as follows:

Concrete Type Minimum Maximum

Drilled Piers 5″ 7″

Portland Cement 1″ 3″ for footings and substructure walls;

4″ for slabs, beams, walls and columns

Concrete to be dosed with superplasticizer

1″ 3″

Normal Weight Concrete after dosing with superplasticizer

4″ 9″

1. The specified slump shall apply at the time when concrete is discharged at the jobsite. Slump tests shall be used to monitor uniformity and consistency of concrete delivered to the job site. They shall not, however, be used as a basis for mix design. Under no circumstances shall the water-cement ratios for concrete exceed those specified.

I. Admixtures. Proportion admixtures according to the manufacturer’s recommendations. Use of an accelerator is permitted when the air temperature is less than 40°F. Use of a retarder is permitted when the temperature of placed concrete exceeds 65°F.

J. Concrete Classification.

1. Structural normal weight concrete specified compressive strength of 4500 psi at 28 days shall have a minimum cement content of 640 lbs./cubic yard.

2. Drilled pier concrete specified compressive strength of 4000 psi at 28 days shall have a minimum cement content of 545 lbs./cubic yard.

3. Light weight roof deck concrete specified compressive strength of 4000 psi at 28 days shall have a minimum cement content of 610 lbs./cubic yard.

4. When fly ash is substituted for part of the cement the minimum cement content shall be a total of the cement plus fly ash.

2.3 MIXING NORMAL WEIGHT CONCRETE

A. Ready-Mixed Concrete.

1. Measure, batch, mix and transport ready-mixed concrete according to ASTM C 94. Plant equipment and facilities shall conform to “Certification of Ready Mixed Concrete Production Facilities (Checklist with instructions)” of the National Ready-Mixed Concrete Association.

2. Provide batch tickets with information specified in ASTM C 94. The batch ticket shall be delivered with the concrete and given to the Owner's on-site testing laboratory representative.


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B. Batch Mixing at Site.

1. Mix concrete in a batch mixer conforming to requirements of the Mixer Manufacturers’ Bureau of the Associated General Contractors of America. Use a mixer equipped with a suitable charging hopper, water storage tank and water measuring device. It must be capable of thoroughly mixing aggregates, cement and water into a uniform mass within the specified mixing time, and of discharging the mix without segregation. Operate the mixer according to the rated capacity and recommended revolutions per minute printed on the manufacturer’s rating plate.

2. Charge the batch into the mixer so that some water will enter in advance of cement and aggregates. Keep water running until one-fourth of specified mixing time has elapsed. Provide controls to prevent discharging until the required mixing time has elapsed. When concrete of normal weight is specified, provide controls to prevent the addition of water during mixing. Discharge the entire batch before the mixer is recharged.

3. Mix each batch of 2 cubic yards or less for not less than 1 minute and 30 seconds. Increase mixing time 15 seconds for each additional cubic yard or fraction of a cubic yard.

4. Keep the mixer clean. Replace pick-up and throw-over blades in the drum when they have lost 10 percent of original depth.

C. Admixtures.

1. Charge air-entraining and chemical admixtures into the mixer as a solution using an automatic dispenser or similar metering device. Measure admixture to an accuracy within + 3 percent. Do not use admixtures in powdered form.

2. Two or more admixtures may be used in the same concrete, provided that the admixtures in combination retain full efficiency and have no deleterious effect on the concrete or on the properties of each other. Inject the admixtures separately during the batching sequence.

3. Add retarding admixtures as soon as practicable after the addition of cement.

4. High-range water reducers (superplasticizers) shall be added to the mix after verifying of the initial slump by the testing laboratory.

D. Temperature Control.

1. When the mean temperature falls below 40°F, keep the as-mixed temperature above 55°F to maintain concrete above the minimum placing temperature.

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 100°F.

3. In hot weather, cool ingredients before mixing to maintain temperature of the concrete below the maximum placing temperature. If necessary, substitute well-crushed ice for all or part of the mixing water.

4. Hot weather and cold weather concreting plans shall be submitted to the Engineer for review as specified in item 1.4, Submittals.


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2.4 MIXING LIGHTWEIGHT CONCRETE

A. Determining Absorption of Aggregates. Mixing procedures vary according to total absorption by weight of lightweight aggregates. Determine total absorption by weight before predamping in accordance with ASTM C 127.

B. Ten Percent or Less Absorption. Follow the same requirements as for mixing normal-weight concrete when preparing concrete made with low-absorptive, lightweight aggregates having 10 percent or less total absorption by weight. To be low-absorptive, the aggregates must have less than 2 percent additional absorption in the first hour after mixing.

C. More Than 10 Percent Absorption. For all concrete made with lightweight aggregates having more than 10 percent total absorption by weight, batch and mix as follows:

1. Place approximately 80 percent of mixing water in the mixer. Add the air-entraining admixture and all aggregates if predampened. Mix for a minimum of 30 seconds or 5 to 10 revolutions of a truck mixer. When aggregates have not been predampened, mix aggregates and water for a minimum of 1 minute and 30 seconds for 15 to 30 revolutions of a truck mixer. Then add the air-entraining admixture and mix for an additional 30 seconds.

2. Then in the following sequence, add specified or permitted admixtures, other than air-entraining agent, all cement and the mixing water previously withheld.

D. Complete the mixing using procedures for normal-weight concrete.

PART 3 - EXECUTION

3.1 GENERAL

A. Concreting Under Water. Will not be permitted.

B. Conveying Equipment. Select equipment of size and design to ensure continuous flow of concrete at the delivery end. Conform to the following equipment and operations requirements:

1. Provide truck mixers, agitators and nonagitating units and manner of operation conforming to requirements of ASTM C 94.

2. Use belt conveyors configured horizontally or at a slope which causes no segregation or loss. Use an approved arrangement at the discharge end to prevent separation. Discharge long runs without separation into a hopper.

3. Provide metal or metal-lined chutes. Arrange for slopes not exceeding 1 vertical to 2 horizontal and not less than 1 vertical to 3 horizontal. Chutes more than 20 feet long and chutes not meeting slope requirements may be used if concrete is discharged into a hopper before distribution.

4. Use of aluminum or aluminum alloy pipe or chutes for conveying concrete is not permitted.

C. Protection from Adverse Weather. Unless adequate protection is provided or approval is obtained, do not place concrete during rain, sleet, snow or freezing weather. Do not permit rainwater to increase mixing water or to damage the surface finish. If rainfall occurs after placing operations begin, provide adequate covering to protect the work.


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D. Hot and Cold Weather Procedures.

1. Hot Weather.

a. Definition. Any combination of high air temperature, low relative humidity, and wind velocity tending to impair the quality of fresh or hardened concrete or otherwise resulting in abnormal properties.

b. Mix Temperature. The temperature of the concrete mixture without set-retarding admixture (ASTM C 494, Type D) shall not exceed 90°F. With a retarding admixture, the temperature may not exceed 100°F. Provide and follow special recommendations from the admixture supplier for dosages appropriate for mix temperatures from 85°F to 100°F. When a pad or mat thickness is 3 feet or more, the foregoing temperatures of mixes shall be reduced by 10°F. Mix temperature will be measured at time of placement. Mix temperature may be lowered by cooling the ingredients, cooling the mixer drum by fog spray, using chilled water or ice in whole or part for the added water, or arranging the delivery sequence so that temperatures generated during the time of transport and placement do not exceed the temperatures specified. Concrete mixes which exceed the specified temperatures shall be rejected.

2. Cold Weather.

a. Definition. Cold weather is defined as a period when, for more than 2 successive days, the mean daily temperature is below 40°F.

b. General. Unless provisions are made in advance, concrete shall not be placed when cold weather conditions are expected. In the event that a freeze does occur, the Contractor shall protect the cast concrete from freezing.

3.2 PREPARATION

Prior to placing concrete, verify that forms are clean and wet or release agent applied and that reinforcing, pipes, conduit, sleeves, thimbles, hangers, anchors, waterstops, expansion joint materials, flashing and other work required to be cast in concrete have been properly installed. Check other trades to ascertain that their work is in place. Verify that surfaces against which concrete will be placed, such as earth or hardened concrete, have been prepared as specified.

3.3 CONCRETE

A. Delivery Schedule. Mix concrete only in quantities for immediate use. Discard concrete which has set. Retempering of set concrete is not permitted. Completely discharge concrete at the project site within 1 hour and 30 minutes after adding cement to aggregate. In hot weather, reduce this time to 1 hour or less to prevent stiffening of concrete before it is placed.


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B. Adjusting Slump. If concrete arrives at the site with slump below that specified, water may be added only with prior approval of the Architect/Engineer. Indiscriminate addition of water to increase slump is prohibited. Do not exceed either the maximum specified permissible water-cement ratio or maximum slump. Any addition of water above the maximum water-cement ratio shall be cause for rejection. Concrete arriving at the project site with a slump greater than 1 inch above maximum specified allowable slump shall be rejected. Allowing truck to turn until slump is within specified allowable limits is not permitted under any circumstances. If mixes continually arrive at the project site with slump of 2 inches or less at the maximum allowable water-cement ratio, use a superplasticizer in the concrete mix. Alternatively sample the aggregates and determine if grading has become finer. If this condition exists, change the mix proportions to accommodate the change but keep the water-cement ratio constant. Any mix adjustments required to obtain specified slump must be approved and directed by the Engineer.

C. Consistency. If concrete arrives with cement balls, balls shall be removed. Excessive balling is grounds for rejection of the concrete. Trucks carrying balled concrete shall have their numbers recorded. If the same truck arrives at the project site carrying balled concrete three times, it will be rejected and not allowed to return to the project site until certification is provided that the problem has been corrected.

3.4 CONVEYING

Handle concrete from mixer to placement as quickly as practicable while providing concrete of required quality in the placement area. Use methods which prevent loss of ingredients and segregation.

3.5 PLACING

A. Procedure.

1. Deposit concrete continuously, or in layers of such thickness that no concrete will be deposited on concrete which has hardened sufficiently to cause formation of seams or cold joints or planes of weakness within the section. If the section cannot be placed continuously, place construction joints as specified or as approved by the Engineer.

2. Proceed with placement at a rate such that concrete which is being integrated with fresh concrete is still plastic. Do not deposit concrete which has partially hardened or has been contaminated by foreign materials.

3. Remove temporary spreaders from forms when the spreader is no longer useful. Temporary spreaders may remain embedded in concrete only if made of galvanized metal or concrete, and if prior approval by the Engineer has been obtained.

4. Do not start placing of concrete in supported elements until concrete previously placed in columns and walls is no longer plastic.

5. Deposit concrete as nearly as practicable in its final position to avoid segregation due to rehandling or flowing. Do not subject concrete to a procedure which will cause segregation.

6. Where surface mortar is to be the basis of a finish, especially those designated to be painted, work coarse aggregate back from forms with a suitable tool to bring the full surface of mortar against the form. Prevent formation of excessive surface voids.


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7. Consolidate concrete by vibration, spading, rodding or forking so that the concrete is thoroughly compacted and worked around reinforcement, around embedded items and into corners of forms. Internal vibrators used shall be the largest size and the most powerful that can be properly used in the work, as described in Table 5.1.4 of ACI 309R. They shall be operated by competent workmen. Insert vibrators into concrete at distances no greater than twice the radius of action as shown in Column 7 of Table 5.1.4, ACI 309. Compact the concrete to a dense mass eliminating air and other planes of weakness. Do not use vibrators to transport concrete within the form. Plunge the vibrator rapidly into the concrete lift penetrating the lift below. Thereafter, manipulate the vibrator in an up-and-down motion and gradually withdraw it from the concrete. At each insertion, the duration shall be sufficient to consolidate the concrete but not sufficient to cause segregation.

a. Maintain a spare vibrator on the site during concrete placement operations. Periodically check the line-in voltage of shaft vibrators to verify that proper power is being received. For flat work, the use of vibrating screeds is encouraged.

b. Vibrator heads used in concrete reinforced with epoxy-coated reinforcing steel shall be nonmetallic or coated to prevent damage to the epoxy coating on the reinforcing steel.

8. If forms become displaced in any way during placing of concrete, immediately stop the operation and do not resume placing until forms have been rebraced and brought back to required lines and levels.

9. Concrete placing procedures and equipment shall not displace reinforcing steel or other embedded items.

3.6 REPAIRING SURFACE DEFECTS AND FINISHING

Conform to the requirements of Section 03360 – Concrete Finishing.

3.7 CURING PROCEDURES

A. Objective. Protect freshly deposited concrete from premature drying and excessively hot or cold temperatures. Maintain a minimal moisture loss and a relatively constant temperature during the time necessary for hydration of cement and proper hardening of concrete.

B. Initial Curing. Immediately after the finishing operation, begin initial curing. Keep concrete continuously moist at least overnight. Use one of the following materials or methods for initial curing:

1. Ponding or continuous sprinkling.

2. Absorptive mat or fabric kept continuously wet.

3. Vapor mist bath.

C. Final Curing. Immediately following the initial curing and before concrete has dried, provide additional curing by one of following materials or methods:

1. Continuing the method used in initial curing.

2. Waterproof paper, polyethylene film or white burlap-polyethylene sheeting.

3. Other moisture-retaining coverings as approved.


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D. Duration of Curing. Continue final curing until the cumulative number of days or fractions of days during which the ambient temperature is above 50°F has totaled 7. If high-early-strength concrete has been used, continue final curing for a total of 3 days. Prevent rapid drying at the end of the curing period.

E. Formed Surfaces. Steel forms heated by the sun and wood forms in contact with concrete during final curing period shall be kept wet. If forms are to be removed during the curing period, employ one of above curing materials or methods immediately. Continue such curing for the remainder of the curing period.

F. Temperature.

1. Cold Weather. When the mean daily temperature of the atmosphere is less than 40°F, maintain the ambient temperature of concrete between 50 and 70°F for the required curing period. When necessary, make arrangements for heating, covering, insulating or housing concrete work in advance of placement to maintain the required temperature and moisture conditions. Prevent injury due to concentration of heat. When combustion heaters are necessary in an enclosed or protected area where concrete slabs are being placed, vent the heaters.

2. Hot Weather. When necessary, make arrangements for installation of windbreaks, shading, fog spraying, sprinkling, ponding or wet covering of light color in advance of placement. Take such protective measures as quickly as concrete hardening and finishing operations will allow.

3. Temperature Changes. Control changes in temperature of concrete at a rate as uniform as possible. Do not permit a temperature change to exceed 5°F in any one hour or 50°F in any 24-hour period.

G. Protection from Mechanical Injury. During the curing period, protect concrete from damaging mechanical disturbances, particularly load stresses, heavy shock and excessive vibration. Protect finished concrete surfaces from damage caused by construction equipment, materials or methods and by rain or running water. Do not load self-supporting structures in any way that overstresses concrete.

3.8 TESTING AND CONTROL FURNISHED BY OWNER

A. Required Services. The commercial testing laboratory specified in Section 01380 will be required to perform the following functions:

1. Verify that the plant equipment and facilities conform to the National Ready-Mix Concrete Association, “Certification of Ready-Mix Concrete Production Facilities (checklist with instructions).”

2. Materials. Test proposed materials for compliance with the specifications.

3. Mix Design. Review the proposed mix design submitted by the Contractor.

4. Production Samples. Obtain production samples of materials at plants or stockpiles during work progress and test for compliance with the specifications.

5. Field Test Cylinders. Obtain samples from every 100 cubic yards and any portion less than 100 cubic yards for each mix design placed in any one day. Conduct strength tests for concrete according to the following procedures:

a. Secure composite samples according to ASTM C 172. Obtain each sample from a different batch of concrete on a representative, random basis. Avoid selecting a test batch by any means other than a random number chosen before concrete placement begins.


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b. Mold four specimens from each sample according to ASTM C 31. Cure under standard moisture and temperature conditions as specified in Sections 7(a) and (b) of ASTM C 31.

c. Test two specimens at 7 days and two specimens at 28 days according to ASTM C 39. For test result, average the strengths of the two specimens. However, if one specimen evidences improper sampling molding or testing, discard it and the remaining cylinder shall be considered the test result. When high-early-strength concrete is specified or approved, test specimens at 3 and 7 days.

6. Air Content. Determine air content of normal weight concrete on a regular and frequent basis according to ASTM C 231.

7. Conduct a slump test at least once for every 25 cubic yards placed.

8. Check concrete temperature at least once for every 25 cubic yards placed.

B. Additional Services. If requested by the Engineer, the commercial testing laboratory may also perform the following additional services:

1. Check batching and mixing operations.

2. Review the manufacturer's report of each cement shipment and conduct laboratory tests.

3. Mold and test reserve 7-day cylinders or field cylinders.

4. Conduct field tests for slump, concrete temperature and ambient temperature.

5. Prepare molds and test shrinkage-compensating concrete for restrained expansion.

C. The Contractor shall notify the commercial testing laboratory, employed by the Owner, 24 hours prior to placing concrete.

3.9 TESTING OF DEFICIENT CONCRETE IN PLACE

A. The strength of the concrete will be considered potentially deficient if the averages of three consecutive strength test results fail to equal or exceed the specified strength or if any individual strength test result falls below the specified strength by more than 500 psi. Core test, structural analysis or load test may be required by the Engineer.

B. Core Tests.

1. Cores at least 2 inches in diameter shall be obtained and tested in accordance with ASTM C 42. If the concrete in the structure will be dry under service conditions, the cores shall be air dried (temperature 60 to 80°F, relative humidity less than 60 percent) for 7 days before test and shall be tested dry. If the concrete in the structure will be more than superficially wet under service conditions, the cores shall be tested after moisture conditioning in accordance with ASTM C 42.

2. At least three representative cores shall be taken from each member or area of concrete in place that is considered potentially deficient. The location of cores shall be determined by the Engineer so as to least impair the strength of the structure. If, before testing, one or more of the cores show evidence of having been damaged subsequent to or during removal from the structure, it shall be replaced.

3. Concrete in the area represented by a core test will be considered adequate if the average strength of the cores is equal to at least 85 percent of the specified strength and if no single core is less than 75 percent of the specified strength.


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4. Core holes shall be patched as specified in Section 03360 – Concrete Finishing.

C. Structural Analysis. If core holes are inconclusive or impractical to obtain, the Engineer may perform additional structural analysis at the Contractor's expense to try to confirm the safety of the structure.

D. Testing by impact hammer, sonoscope, or other nondestructive device may be permitted by the Engineer to determine relative strengths at various locations in the structure as an aid in evaluating concrete strength in place or for selecting areas to be cored. Such tests, unless properly calibrated and correlated with other test data, shall not be used as a basis for acceptance or rejection of the structure’s safety.

E. Concrete work judged inadequate by core tests, structural analysis shall be replaced at the Contractor’s expense.

F. The Contractor shall pay all costs, including all costs due to delays, incurred in providing the additional testing and/or analysis required.

END OF SECTION


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BLANK PAGE


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CONCRETE FINISHING 03360-1

SECTION 03360

CONCRETE FINISHING

PART 1 - GENERAL

1.1 SUMMARY

This section provides requirements for the repairing of surface defects, repairing of cracks, finishing of concrete surfaces including both formed and unformed, sealing of concrete surfaces, installation of concrete fill and topping.

1.2 RELATED WORK

Coordinate the requirements of this section with all other sections of Division 3 - Concrete.

1.3 SUBMITTALS

A. When substitutions are proposed by the Contractor as equal to brands of materials specified herein, submit brochures and samples of proposed substitutions for approval before delivery to the project.

B. Acceptable brands are listed herein. If products are different from those listed, submit manufacturer's technical literature on product brands, proposed for use by the Contractor, for review. The submittal shall include the manufacturer's technical information with evidence that the proposed is equal to listed brands, the installation and/or application instruction. Submittals shall be made on the following products:

1. Proprietary patching material.

2. Epoxy adhesive.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Bonding Grout. Prepare bonding grout by mixing approximately one part cement to one part fine sand passing a No. 30 mesh sieve. Mix with water to a consistency of thick cream. As an alternate bonding grout, the Contractor may use a commercially prepared bonding agent used in strict accordance with the manufacturer's recommendations and instructions. The bonding agent must be suitable for use continuously submerged in wastewater. Certification by the manufacturer will be required. Submit manufacturer's technical information on any proposed bonding agent.

B. Patching Mortar.

1. Make patching mortar of the same materials and of approximately the same proportions as concrete, except omit coarse aggregate. Substitute white Portland cement for part of the gray Portland cement on exposed concrete in order to produce a color matching the color of surrounding concrete. Determine color by making a trial patch. Use the minimum amount of mixing water required for handling and placing. Mix patching mortar in advance and allow to stand. Mix frequently with a trowel until it has reached the stiffest consistency that will permit placing. Do not add water.

2. If permitted or required, proprietary compounds for adhesion or as patching ingredients may be used in lieu of or in addition to the foregoing patching materials. Use such compounds according to the manufacturer's recommendations. Material must be suitable for use under continuously submerged conditions. Certification by the manufacturer will be required.


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C. Epoxy Adhesive. The compound shall be a 2-component, 100 percent solids, 100 percent reactive compound suitable for use on dry or damp surfaces, "Euco Epoxy No. 452MV" or "Eucoepoxy LPL" by The Euclid Chemical Company, "Sikadure Hi-Mod" by The Sika Chemical Corporation, or approved equal.

PART 3 - EXECUTION

3.1 REPAIRING SURFACE DEFECTS

A. Defective Areas. Repair defective areas immediately after the removal of forms. Remove honeycombed and other defective concrete down to sound concrete but in no case to a depth less than 1 inch. Make edges of cuts perpendicular to the concrete surface. Thoroughly coat the surface with a bonding grout containing the bonding admixture. The bonding agent must be used in conformance with the manufacturer's recommendations and instructions. While the bonding coat is still tacky, apply the premixed patching mortar. Thoroughly consolidate the mortar into place and strike off to leave the patch slightly higher than the surrounding surface. To permit initial shrinkage, leave undisturbed for at least 1 hour before final finishing. Keep the patched area damp for 7 days. Do not use metal tools in finishing patches in a formed wall which will be exposed.

B. Tie Holes. Patch the holes immediately after removal of forms. After cleaning and thoroughly dampening the tie hole, fill solid with patching mortar.

C. Cracks. Cracks in excess of 0.01 inch shall be repaired by pressure injection of a moisture-insensitive, epoxy-resin system. Submit proposed material and method of repair for approval prior to making repairs.

D. Structural Repair. Any required structural repairs shall be made after prior approval of the Engineer as to method and procedure, using the specified epoxy adhesive and/or approved epoxy mortar.

3.2 FINISHING OF FORMED SURFACES

A. Unfinished Surfaces. A finish is not required on surfaces concealed from view by earth, water, etc., in the completed structure except as specified otherwise.

B. Rough Form Finish.

1. No form facing material is required on rough form finish surfaces.

2. Patch tie holes and defects, and fins exceeding 1/4 inch in height shall be chipped off.

3. A rough form finish may be used on concrete surfaces which will be concealed from view by earth in the completed structure except the top 2 feet of walls below final top of ground elevation and full depth of grade beams shall have a smooth form finish. In addition, surfaces scheduled to be permanently exposed during future expansion, at locations shown on the drawings, shall have a smooth form finish.

C. Smooth Form Finish.

1. The form facing shall produce a smooth, hard, uniform texture on the concrete. Use plywood or fiberboard linings or forms in as large sheets as practicable and with smooth, even edges and close joints.

2. Patch tie holes and defects. Rub fins and join marks with wooden blocks to leave a smooth, unmarred finished surface. Remove all sharp edges on surfaces to receive a protective liner.


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3. Provide a smooth form finish on all formed surfaces not concealed from view by earth in the completed structure. In addition, walls that will be exposed after future construction, at locations shown on the drawings, shall have a smooth form finish. Smooth form finish on exterior face of exterior walls shall extend 2 feet below final top of ground elevation. The exterior face of all perimeter grade beams shall have a smooth form finish for the full depth of the grade beam.

D. Related Unformed Surfaces. Tops of walls and similar unformed surfaces occurring adjacent to formed surfaces shall be struck smooth after concrete is placed. Float unformed surfaces to a texture reasonably consistent with that of the formed surfaces. Final treatment on formed surfaces shall continue uniformly across the unformed surfaces.

3.3 FINISHING SLABS AND SIMILAR FLAT SURFACES TO CLASS A, B OR C FINISH

A. Shaping to Contour. Use strike-off templates or approved compacting-type screeds riding on screed strips or edge forms to bring concrete surface to the proper contour. See Section 03100, Concrete Formwork for edge forms and screeds. This system shall be used throughout the project.

B. Consolidation. Thoroughly consolidate concrete in slabs and use internal vibration in beams and girders of framed slabs and along bulkheads of slabs on grade. Obtain consolidation of slabs and floors with vibrating bridge screeds, roller pipe screeds, or other approved means. Concrete to be consolidated must be as dry as practicable. Do not permit manipulation of surfaces prior to finishing operations.

C. Tolerances for Finished Surfaces. Tolerances are checked by placing a straightedge of specified length anywhere on the slab. The gap between slab and straightedge must not exceed the tolerance listed for the specified class.

Class Straightedge Length (ft.) Tolerance (in.)

A 10 ⅛

B 10 ¼

C 2 ¼

D. Raked Finish. After concrete has been placed, struck off, consolidated and leveled to Class C tolerance, roughen the surface before final set. Roughen with stiff brushes or rakes to a depth of approximately 1/4 inch. Notify the Engineer prior to placing concrete requiring the initial raked surface finish so that an acceptable raked finish standard may be established for the project. Provide a raked finish for surfaces to receive bonded concrete fill.

E. Floated Finish.

1. After concrete has been placed, struck off, consolidated and leveled, do not work further until ready for floating. Begin floating when water sheen has disappeared, or when the mix has stiffened sufficiently to permit proper operation of a power-driven float. Consolidate the surface with power-driven floats. Use hand floating with wood or cork-faced floats in locations inaccessible to a power-driven machine and on small, isolated slabs.


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2. Recheck tolerance of the surface after initial floating with a 10-foot straightedge applied at not less than two different angles. Cut down high spots and fill low spots to Class B tolerance. Immediately refloat slab to uniform, smooth, granular texture.

3. Provide a floated finish for the following:

a. Floor slabs of liquid-containing structures.

b. Pit floors, trench floors and curbed areas.

c. Exterior floor slabs and concrete walkways, unless noted otherwise.

F. Broom or Belt Finish.

1. Immediately after completing the floated finish, draw a broom or burlap belt across the surface to give a coarse transverse scored texture.

2. Provide a broom or belt finish for ramps.

3.4 BONDED CONCRETE FILL

A. Surface Preparation.

1. Protect the raked, base-slab finish from contamination until the time of placing fill. Mechanically remove oil, grease, asphalt, paint, clay stains or other contaminants, leaving a clean surface.

2. Prior to placement of the fill, thoroughly dampen the roughened slab surface and leave free of standing water. Immediately before fill is placed, scrub a coat of bonding grout onto the surface. Do not allow the grout to set or dry before the fill is placed.

B. Concrete Fill.

1. Concrete shall have a 28-day compressive strength of 4000 psi with a maximum coarse aggregate size of 3/8 inch, as specified in Section 03310 – Cast-in-Place Concrete.

2. Surfaces of concrete fill shall be given a wood float finish.

3. Provide concrete fill at all locations shown on the drawings.

3.5 CURING

Curing of concrete shall conform to the requirements of Section 03310 – Cast-in-Place Concrete.

END OF SECTION


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NONSHRINK GROUT 03605-1

SECTION 03605

NONSHRINK GROUT

PART 1 - GENERAL

1.1 SUMMARY

This section provides requirements for nonmetallic nonshrink grout for leveling column base plates, steel beams bearing on concrete, machinery and other equipment, for anchoring handrail posts into sleeves embedded in concrete, and at all other locations shown or reasonably implied by the drawings.

1.2 RELATED WORK

Coordinate work of this section with all other sections. Review all drawings and specifications for items to be grouted with nonshrink grout.

A. Cast-in-Place Concrete. Section 03310.


A. American Society for Testing and Materials (ASTM).

1. ASTM C 309 - Standard Specification for Liquid Membrane-Forming Compounds for Curing Concrete.

2. ASTM C 1107 - Standard Specification for Packaged Dry, Hydraulic Cement Grout (Nonshrink).

1.4 SUBMITTALS

Acceptable brands of materials are specified herein. If substitutions are proposed by the Contractor, submit the following information on the proposed substitution for approval before delivery to the project:

A. Manufacturer's technical literature including manufacturer's specifications for mixing and placing of the grout.

B. Results of tests performed by a certified independent testing laboratory showing conformance to ASTM C 1107 and the requirements of this specification.

C. Provide test data from an independent laboratory indicating that the grout, when placed at a fluid consistency, will achieve 95 percent bearing under a 4-foot by 4-foot base plate.

1.5 MANUFACTURER'S ASSISTANCE

Manufacturers of proprietary products shall make available, at no cost and upon 72 hours' notification, the services of a qualified, full-time employee to aid in assuring proper use of the product under job conditions.

1.6 DELIVERY AND STORAGE

A. Nonshrink grout shall be delivered to the project in unopened containers and shall bear intact manufacturer's labels.

B. Store all nonshrink grout material in dry shelter and protect from moisture.

C. Containers that are torn or damaged such that the nonshrink grout material has been exposed to the elements shall be discarded.


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PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. The Euclid Chemical Company, "Euco N-S Grout."

B. Master Builders, "Masterflow 713."

C. U.S. Grout Corporation, "Five Star Grout."

D. Or approved substitution.

2.2 NONSHRINK GROUT

Grout shall contain nonmetallic natural aggregate and shall be nonstaining and noncorrosive. Grout shall be preblended factory-packaged material manufactured, under rigid quality control, specifically for use in transferring heavy loads. The nonshrink grout shall conform to the following requirements:

A. ASTM C 1107, Grade C.

B. Resist attack by oil and water.

C. Have minimum initial setting time of approximately 1 hour at 70 F.

D. Have a minimum compressive strength in the fluid consistency of 6500 psi at 28 days.

E. Shall not contain any chlorides or additives which may contribute to corrosion.

F. Shall be non-bleeding and non-segregating at a fluid consistency.

G. Provide total shrinkage compensation which provides a maximum bearing surface for the greatest overall support.

H. Free of gas-producing or gas-releasing agents.

2.3 WATER

Water used for mixing the grout shall be potable.

2.4 PEA GRAVEL

Clean pea gravel conforming to ASTM C 33 coarse aggregate graded so that at least 90 percent passes a 3/8-inch sieve and 90 percent is retained by a No. 4 sieve.

2.5 MEMBRANE-FORMING CURING COMPOUND

Conform to the requirements of Section 03310 – Cast-in-Place Concrete.

PART 3 - EXECUTION

3.1 PROCEDURES

Installation methods and procedures shall conform to the printed instructions of the grout manufacturer and these specifications. Where there is a conflict between these specifications and the printed instructions of the grout manufacturer, the printed instructions of the grout manufacturer shall take precedence.

3.2 PREPARATION

A. Remove all defective concrete, laitance, dirt, oil, grease and other foreign material from concrete surfaces by bush-hammering, chipping or other similar means, until a sound, clean concrete surface is achieved.

B. Lightly roughen the concrete, but not enough to interfere with the proper placement of grout.


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C. Remove foreign materials from all surfaces in contact with grout.

D. Align, level and maintain final positioning of all components to be grouted. Coat shim with a thin film of grease or wax to facilitate removal.

E. Provide relief holes to avoid trapping air beneath the base plate.

F. Take special precautions during extreme weather conditions according to the manufacturer's written instructions.

G. Saturate all concrete surfaces with clean water for the period of time specified by the manufacturer. Remove excess water and leave none standing.

H. Immediately before grouting, clean any contaminated surfaces.

3.3 FORMWORK

A. Build leak proof forms that are strong and securely anchored and shored to withstand grout pressures. Forms shall be built high enough to provide a "head" of grout where it is required to force grout into difficult locations.

B. Provide enough clearance between the formwork and the area to be grouted to permit proper placement of grout.

3.4 MIXES

A. For less than a 4-inch clearance, or where size or shape of space makes grouting difficult, grout mix shall consist of grout material and water.

B. For greater than 4-inch clearances where coarse aggregate will not obstruct free passage of the grout, the grout may be extended by adding clean pea gravel if allowed or recommended by the grout manufacturer. Follow the manufacturer's recommendation for the maximum amount of pea gravel that may be added.

C. Use the minimum amount of water necessary to produce a flowable grout without causing either segregation or bleeding.

3.5 MIXING

A. Mixing of nonshrink grout shall be in strict conformance to the recommendations of the grout manufacturer.

B. Mix grout as close to the work area as possible and transport the mixture quickly and in a manner that does not permit segregation of materials.

C. After the grout has been mixed, do not add more water for any reason.

3.6 PLACING

A. Place nonshrink grouting material quickly and continuously by the most practical means permissible: pouring, pumping or under gravity pressure. Do not use either pneumatic-pressure or dry packing methods without written permission of the Engineer.

B. Follow established concreting procedures observing precautions for hot and cold weather concreting.

C. When practical, apply grout from one side only to avoid entrapping air.

D. Final installation shall be thoroughly compacted and free from air pockets. To facilitate placement, a 1/2- to 1-inch chain or metal strap may be pulled back and forth under the equipment during grouting. Remove chain or strap before initial set takes place.

E. Do not vibrate the placed grout mixture or allow it to be placed if the area is being vibrated by nearby equipment, except when approved by the grout manufacturer.


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F. Do not remove leveling shims for at least 48 hours after grout has been placed. After shims have been removed, fill voids with nonshrink grout.

3.7 CURING

Cure grout for 3 days after placing by keeping wet and covering with curing paper, by coating with a concrete membrane-forming curing compound, or by other approved method.

END OF SECTION


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STRUCTURAL STEEL

05120-1

SECTION 05120

STRUCTURAL STEEL

PART 1 - GENERAL

1.1 SUBSTITUTIONS

Substitution of rolled sections, details or products is not permitted without prior approval of the Engineer. If items shown are not readily obtainable, permission to substitute for the specified item may be requested by the Contractor. Substitutions may be allowed by the Engineer on items of equal or superior properties which conform to design criteria.


Unless specified or detailed otherwise, comply with the applicable provisions of the following:

A. AISC Specification for Structural Steel for Building Allowable Stress Design.

B. AISC Code of Standard Practice for Steel Buildings and Bridges.


Schedule material and delivery so that items may be erected promptly after arrival. If materials must be stored at the project site, they shall be stored above ground on platforms, skids or other supports. Material stored at the site shall be kept free of dirt, mud, grease or oil. Protect stored material from corrosion.

1.4 SUBMITTALS

Submittals shall be in accordance with Section 01330. Submit shop drawings and certifications to the Engineer.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Structural Steel.

1. All structural steel W, WT and channel sections shall conform to the requirements of ASTM A992, Fy =50ksi

2. All miscellaneous structural shapes, plates and bars shall conform to the requirements of ASTM A36, Fy = 36ksi. Where indicated on the Drawings, structural shapes, plates, sheet piling and bars shall conform to the requirements of ASTM A572, Grade 50.

3. Clip angles, stiffeners, plates and other detail items must conform to standard of the main member to which the items are attached unless specifically excepted.

B. Steel Pipe. Conform to ASTM A53, Type E or S, Grade B, welded or seamless. No hydrostatic tests required.

C. HSS Round Structural Steel. Conform to ASTM A500, Grade B, Fy =42ksi requirements.

D. HSS Square or Rectangular Steel. Conform to ASTM A500, Grade B, Fy = 46ksi requirements.

E. Bolts. Conform to the following standards unless indicated otherwise.

1. High-Strength Bolts with Suitable Nuts and Hardened Washers. ASTM A325.

2. All high-strength bolts, nuts and washers shall be hot-dip galvanized.


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STRUCTURAL STEEL

05120-2

3. Standard Machine Bolts. ASTM A307, Grade A, galvanized. Nuts shall be heavy hex conforming to ASTM A563, Grade A or better, galvanized.

4. Anchor Bolts for Structural Steel. F 1554, Grade 55 threaded rod, galvanized. Nuts shall be heavy hex conforming to ASTM A563, Grade A or better, galvanized. Provide oversized washers with all anchor bolts.

5. Threaded Rods. ASTM A36, galvanized.

6. Galvanizing shall conform to the requirements of ASTM A153.

F. Stainless Steel. All bolts, anchor bolts, expansion bolts, plates, shapes, etc., indicated on the drawings as "stainless steel," "stn steel" or "SS" shall be stainless steel furnished as specified in Section 05550, Bolts, Anchor Bolts, Expansion Anchors and Concrete Inserts.

G. Shear Connectors. ASTM A 108, Grades 1015 through 1020, headed-stud type, cold-finished carbon steel; AWS D1.1/D1.1M, Type B. Prepare steel surfaces as recommended by manufacturer of shear connectors. Use automatic end welding of headed-stud shear connectors according to AWS D1.1/D1.1M and manufacturer's written instructions.

H. Welding Electrodes. Equivalent to AWS Low Hydrogen E 70 Series suitable for the welding process used.

I. Galvanizing Repair Coating. Hot-applied zinc-based solder conforming to the requirements of ASTM A780.

J. Paint for Shop Coat. Conform to the following:

1. Section 09928 – Protective Coatings System.

K. Grout. Non-shrink grout in accordance with Section 03605 – Non-Shrink Grout.

2.2 FABRICATION

A. Do not begin fabrication of structural steel until after shop drawings have been reviewed and accepted by the Engineer. Fabricate according to reviewed shop drawings, reference standards and these specifications unless shown otherwise. This specification shall govern when it is a conflict with the referenced standards.

B. Connections.

1. Shop connections shall be bolted or welded, as shown on the drawings.

2. Field connections shall be bolted, as shown on the drawings.

3. Bolted connections may be either ASTM A307 bolt connections, ASTM A325 high-strength bolt bearing-type connections, or ASTM A325 high-strength bolt slip critical connections. The type of connection required at each location shall be as shown on the drawings or indicated in the General Notes. When not shown on the drawings or indicated in the General Notes, use ASTM A307.

4. Column base plates shall be shop welded to the columns.


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05120-3

C. Drill, punch, cut and tap steel as required for anchorage, connection, or accommodating the work of other trades as shown, specified, or otherwise directed by the Engineer. All holes, slots, etc., and required reinforcing shall be shown on shop drawings. If any such holes, slots, etc., are not shown on drawings, they shall be immediately brought to the attention of the Engineer and members shall be reinforced if, and as directed by, the Engineer. Items with burn holes are considered defective and must be removed and replaced.

D. All members shall have a piece mark. Piece marks shown on the steel members delivered to the job site shall correspond to piece marks shown on the shop details and erection diagrams.

2.3 WELDING

A. Perform welding in accordance with the AWS D1.1. Use procedures such as preheat or interpass temperature as recommended by AWS.

B. Welding process and procedures shall be the most suitable process for the connection as selected by the Contractor and approved by the Engineer. The Contractor's proposed welding process shall be shown on the shop drawings.

C. All shop and field welding shall be performed by qualified welders who hold current welding certificates.

D. Surfaces to be welded shall be free of loose scale, slag, rust, grease, paint and other foreign material. Mill scale which withstands vigorous wire brushing may remain.

E. Joint surfaces shall be free of fins and tears caused by shearing. Wherever practicable, prepare edges by gas cutting using a mechanically guided torch.

F. Protect electrodes from exposure to moisture and coating.

G. If shop welding is done by automatic, submerged arc process, verify that physical properties of deposited weld metal will be similar to properties of the base metal.

H. No welding shall be done when the temperature of the base metal is below 32˚F.

I. The cover bead or finish pass must have a smooth, uniform surface with reinforcement of 1/16 to 1/8 inch. Surface voids, cracks in finish weldments, or undercutting of base metal at the fusion line is not acceptable.

J. In all lapped or "tee" splices or other joints using intermittent fillet welds, the edges of faying surfaces shall be continuously seal welded in addition to the required strength weld.

2.4 GALVANIZING

A. All structural Steel shall be hot-dipped galvanized after fabrication. Conform to applicable provisions of ASTM A153, ASTM A384 and ASTM A385.

B. The Contractor shall safeguard against warpage and distortion during hot-dip galvanizing as specified in ASTM A384. Any member or assembly that is warped or distorted shall be straightened. Any member or assembly that cannot be straightened shall be replaced at no additional cost to the Owner.

2.5 SHOP PAINTING

A. Shop prime steel where indicated in plans except as follows:

1. Surfaces to be galvanized.

2. Surfaces to be welded.


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05120-4

3. Contact surfaces of high-strength friction-type bolted connections.

4. Steel to be encased in concrete.

B. Shop painting shall conform to the requirements of Section 09928 – Protective Coatings Systems.

PART 3 - EXECUTION

3.1 ERECTION

A. Erect structural steel according to referenced standards, reviewed shop drawings and these specifications. This specification shall govern when it is in conflict with referenced standards. Contractor shall strictly adhere to the applicable requirements of OSHA, local codes or any regulatory agency or body having jurisdiction over the project.

B. The Contractor shall be fully responsible for furnishing and installing any temporary braces, ties, or shoring necessary to hold secure and safe all erected portions of the structure, under the action of wind and erection loads imposed thereon until construction is completed.

C. Furnish templates for setting anchor bolts in concrete.

D. Give careful attention to leveling and plumbing of structural steel at all stages of construction.

E. Support column base plates on steel wedges with no portion of a wedge within 1 inch of base plate edge. Apply grout under base plates according to manufacturer's recommendations.

F. Drift pins may be used only to bring parts together if used carefully so as not to distort or damage metal.

G. Welded connections shall conform to the requirements of AWS D1.1, Structural Welding Code – Steel.

H. Field-welded shear connectors shall be visual inspected and tested according to requirements in AWS D1.1/D1.1M for stud welding. Perform bend tests if visual inspections reveal either a less-than-continuous 360-degree flash or welding repairs to any shear connector.

I. Bolted Connections.

1. ASTM A307 bolts shall be snug tight.

2. Install high-strength bolts in accordance with the requirements of the RCSC referenced standard. Bolts shall be tightened by the turn-of-the-nut method.

J. Use of a gas cutting torch for correcting fabrication errors in the field will not be permitted on major members. On minor members not under stress, corrections may be allowed upon prior written approval of the Engineer.


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05120-5

3.2 COATING REPAIRS

A. Shop Primed Surfaces. Thoroughly clean field welds, abrasions, and damaged or defective areas of shop primed surfaces. Prepare the surface as previously specified for shop painting. After the surface is prepared, apply a matching heavy coat of shop paint.

B. Galvanized Surfaces. Prepare the damaged surface and apply a minimum of 2 mils hot-applied galvanizing repair coating in conformance with the requirements of ASTM A780. Where the repair coating manufacturer's recommendations are more stringent than ASTM A780, the manufacturer's recommendations shall be followed.

END OF SECTION


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BLANK PAGE


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SUPPORT FRAMING 05450-1

SECTION 05450

SUPPORT FRAMING

PART 1 GENERAL

1.1 SUMMARY

Furnish and install metal framing, including channels, fittings, clamps, hardware and brackets.

PART 2 PRODUCTS

2.1 MANUFACTURER

Unistrut, Power Strut, or approved substitution.

2.1 MATERIALS

Make channels, fittings, clamps and brackets of sheet steel or of malleable cast iron. Fabricate threaded fasteners of stainless steel.

2.1 COATINGS

A. Galvanizing. Hot-dip galvanize all steel components.

B. PVC. At the factory, apply a minimum 10-mil-thick PVC coating, bonded to metal.

C. Electroplating. Electroplate threaded steel fasteners with cadmium.

2.1 SIZES

Provide channels fabricated from not less than 12-gauge sheet steel, 1-5/8 inches wide and not less than 1-5/8 inches deep.

PART 3 EXECUTION

3.1 APPLICATION

Use hot-dipped galvanized steel components in all areas. Use PVC-coated components when exposed to the weather or when located in a corrosive atmosphere.

3.1 SUPPORTS

Provide metal framing for utility tunnel and trapeze pipe supports and to support large or heavy wall-mounted equipment, wall-mounted raceways, ceiling-hung raceways, and electrical switchgear and panels.

3.1 ANCHOR BOLTS

Use 1/2-inch diameter by 3 inches long epoxy grouted anchor bolts to attach framing to concrete. Space bolts a maximum of 24 inches on center, with not less than two bolts per piece of framing.

3.1 TOUCH-UP

Touch up all scratches or cuts on steel components with an approved zinc chromate or a 90 percent zinc paint. Use a PVC compound on PVC-coated components.

END OF SECTION


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SUPPORT FRAMING 05450-2

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METAL FABRICATIONS 05500-1

SECTION 05500

METAL FABRICATIONS

PART 1 GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.

1.2 SUMMARY

A. Section Includes:

1. Steel framing and supports for mechanical and electrical equipment.

2. Steel framing and supports for applications where framing and supports are not specified in other Sections.

3. Metal bollards.

4. Loose bearing and leveling plates for applications where they are not specified in other Sections.

5. Driveway access gates and posts

B. Products furnished, but not installed, under this Section:

1. Anchor bolts, steel pipe sleeves, slotted-channel inserts, and wedge-type inserts indicated to be cast into concrete or built into unit masonry.

2. Steel weld plates and angles for casting into concrete for applications where they are not specified in other Sections.

1.3 PERFORMANCE REQUIREMENTS

A. Thermal Movements: Allow for thermal movements from ambient and surface temperature changes acting on exterior metal fabrications by preventing buckling, opening of joints, overstressing of components, failure of connections, and other detrimental effects.

1. Temperature Change: 120 deg F, ambient; 180 deg F, material surfaces.

1.4 ACTION SUBMITTALS

A. Product Data: For the following:

1. Nonslip aggregates and nonslip-aggregate surface finishes.

2. Paint products.

3. Grout.

B. Shop Drawings: Show fabrication and installation details for metal fabrications.

1. Include plans, elevations, sections, and details of metal fabrications and their connections. Show anchorage and accessory items.

C. Samples for Verification: For each type and finish of extruded nosing and tread.


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D. Delegated-Design Submittal: For installed products indicated to comply with performance requirements and design criteria, including analysis data signed and sealed by the qualified professional engineer responsible for their preparation.

1.5 INFORMATIONAL SUBMITTALS

A. Qualification Data: For qualified professional engineer.

B. Mill Certificates: Signed by manufacturers of stainless-steel certifying that products furnished comply with requirements.

C. Welding certificates.

D. Paint Compatibility Certificates: From manufacturers of topcoats applied over shop primers certifying that shop primers are compatible with topcoats.


A. Welding Qualifications: Qualify procedures and personnel according to AWS D1.1/D1.1M, "Structural Welding Code - Steel."

B. Welding Qualifications: Qualify procedures and personnel according to the following:

1. AWS D1.1/D1.1M, "Structural Welding Code - Steel."

2. AWS D1.2/D1.2M, "Structural Welding Code - Aluminum."

3. AWS D1.6, "Structural Welding Code - Stainless Steel."

1.7 PROJECT CONDITIONS

A. Field Measurements: Verify actual locations of walls and other construction contiguous with metal fabrications by field measurements before fabrication.

1.8 COORDINATION

A. Coordinate selection of shop primers with topcoats to be applied over them. Comply with paint and coating manufacturers' written recommendations to ensure that shop primers and topcoats are compatible with one another.

B. Coordinate installation of anchorages and steel weld plates and angles for casting into concrete. Furnish setting drawings, templates, and directions for installing anchorages, including sleeves, concrete inserts, anchor bolts, and items with integral anchors, that are to be embedded in concrete or masonry. Deliver such items to Project site in time for installation.

PART 2 PRODUCTS

2.1 METALS, GENERAL

A. Metal Surfaces, General: Provide materials with smooth, flat surfaces unless otherwise indicated. For metal fabrications exposed to view in the completed Work, provide materials without seam marks, roller marks, rolled trade names, or blemishes.

2.2 FERROUS METALS

A. Recycled Content of Steel Products: Postconsumer recycled content plus one-half of preconsumer recycled content not less than 25 percent.


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B. Steel Plates, Shapes, and Bars: ASTM A 36/A 36M.

C. Stainless-Steel Sheet, Strip, and Plate: ASTM A 240/A 240M or ASTM A 666, Dual Cer-tified, Type 304/304L or Type 316/316L as shown on the Drawings.

D. Stainless-Steel Bars and Shapes: ASTM A 276, Dual Certified, Type 304/304L or Type 316/316L as shown on the Drawings.

E. Rolled-Steel Floor Plate: ASTM A 786/A 786M, rolled from plate complying with ASTM A 36/A 36M or ASTM A 283/A 283M, Grade C or D.

F. Rolled-Stainless-Steel Floor Plate: ASTM A 793.

G. Abrasive-Surface Floor Plate: Steel plate with abrasive material metallically bonded to steel.

1. Products: Subject to compliance with requirements, available products that may be incorporated into the Work include, but are not limited to, the following:

a. IKG Industries, a division of Harsco Corporation; Mebac.

b. SlipNOT Metal Safety Flooring, a W. S. Molnar company; SlipNOT.

c. Or approved equal.

H. Steel Tubing: ASTM A 500, cold-formed steel tubing.

I. Steel Pipe: ASTM A 53/A 53M, standard weight (Schedule 40) unless otherwise indicated.

J. Slotted Channel Framing: Cold-formed metal box channels (struts) complying with MFMA-4.

1. Size of Channels: As indicated on Drawings..

2. Material: Galvanized steel, ASTM A 653/A 653M, structural steel, Grade 33, with G90 coating; 0.079-inch nominal thickness.

3. Material: Cold-rolled steel, ASTM A 1008/A 1008M, structural steel, Grade 33; 0.0966-inch minimum thickness; hot-dip galvanized after fabrication.

K. Cast Iron: Either gray iron, ASTM A 48/A 48M, or malleable iron, ASTM A 47/A 47M, unless otherwise indicated.

2.3 NONFERROUS METALS

A. Aluminum Plate and Sheet: ASTM B 209, Alloy 6061-T6.

B. Aluminum Extrusions: ASTM B 221, Alloy 6063-T6.

C. Aluminum-Alloy Rolled Tread Plate: ASTM B 632/B 632M, Alloy 6061-T6.

D. Aluminum Castings: ASTM B 26/B 26M, Alloy 443.0-F.

E. Bronze Plate, Sheet, Strip, and Bars: ASTM B 36/B 36M, Alloy UNS No. C28000 (muntz metal, 60 percent copper).

F. Bronze Extrusions: ASTM B 455, Alloy UNS No. C38500 (extruded architectural bronze).

G. Bronze Castings: ASTM B 584, Alloy UNS No. C83600 (leaded red brass) or No. C84400 (leaded semired brass).

H. Nickel Silver Extrusions: ASTM B 151/B 151M, Alloy UNS No. C74500.


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I. Nickel Silver Castings: ASTM B 584, Alloy UNS No. C97600 (20 percent leaded nickel bronze).

2.4 FASTENERS

A. General: Unless otherwise indicated, provide Type 304 stainless-steel fasteners for exterior use and zinc-plated fasteners with coating complying with ASTM B 633 or ASTM F 1941, Class Fe/Zn 5, at exterior walls. Select fasteners for type, grade, and class required.

1. Provide stainless-steel fasteners for fastening aluminum.

2. Provide stainless-steel fasteners for fastening stainless steel.

3. Provide stainless-steel fasteners for fastening nickel silver.

4. Provide bronze fasteners for fastening bronze.

B. Steel Bolts and Nuts: Regular hexagon-head bolts, ASTM A 307, Grade A; with hex nuts, ASTM A 563; and, where indicated, flat washers.

C. Steel Bolts and Nuts: Regular hexagon-head bolts, ASTM A 325, Type 3; with hex nuts, ASTM A 563, Grade C3; and, where indicated, flat washers.

D. Stainless-Steel Bolts and Nuts: Regular hexagon-head annealed stainless-steel bolts, ASTM F 593; with hex nuts, ASTM F 594; and, where indicated, flat washers; Alloy Group 2.

E. Anchor Bolts: ASTM F 1554, Grade 36, of dimensions indicated; with nuts, ASTM A 563; and, where indicated, flat washers.

1. Hot-dip galvanize or provide mechanically deposited, zinc coating where item being fastened is indicated to be galvanized.

F. Eyebolts: ASTM A 489.

G. Machine Screws: ASME B18.6.3.

H. Lag Screws: ASME B18.2.1.

I. Wood Screws: Flat head, ASME B18.6.1.

J. Plain Washers: Round, ASME B18.22.1.

K. Lock Washers: Helical, spring type, ASME B18.21.1.

L. Anchors, General: Anchors capable of sustaining, without failure, a load equal to six times the load imposed when installed in unit masonry and four times the load imposed when installed in concrete, as determined by testing according to ASTM E 488, conducted by a qualified independent testing agency.

M. Cast-in-Place Anchors in Concrete: Either threaded type or wedge type unless otherwise indicated; galvanized ferrous castings, either ASTM A 47/A 47M malleable iron or ASTM A 27/A 27M cast steel. Provide bolts, washers, and shims as needed, all hot-dip galvanized per ASTM F 2329.

N. Post-Installed Anchors: Torque-controlled expansion anchors or chemical anchors.

1. Material for Interior Locations: Carbon-steel components zinc plated to comply with ASTM B 633 or ASTM F 1941, Class Fe/Zn 5, unless otherwise indicated.


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2. Material for Exterior Locations and Where Stainless Steel is Indicated: Alloy Group 2 stainless-steel bolts, ASTM F 593, and nuts, ASTM F 594.

O. Slotted-Channel Inserts: Cold-formed, hot-dip galvanized-steel box channels (struts) complying with MFMA-4, 1-5/8 by 7/8 inches by length indicated with anchor straps or studs not less than 3 inches long at not more than 8 inches o.c. Provide with temporary filler and tee-head bolts, complete with washers and nuts, all zinc-plated to comply with ASTM B 633, Class Fe/Zn 5, as needed for fastening to inserts.

2.5 MISCELLANEOUS MATERIALS

A. Welding Rods and Bare Electrodes: Select according to AWS specifications for metal alloy welded.

B. Low-Emitting Materials: Paints and coatings shall comply with the testing and product requirements of the California Department of Health Services' "Standard Practice for the Testing of Volatile Organic Emissions from Various Sources Using Small-Scale Environmental Chambers."

C. Shop Primers: Provide primers that comply with Specification Section 09928 – Protective Coating Systems.

D. Universal Shop Primer: Fast-curing, lead- and chromate-free, universal modified-alkyd primer complying with MPI#79 and compatible with topcoat.

1. Use primer containing pigments that make it easily distinguishable from zinc-rich primer.

E. Galvanizing Repair Paint: High-zinc-dust-content paint complying with SSPC-Paint 20 and compatible with paints specified to be used over it.

F. Bituminous Paint: Cold-applied asphalt emulsion complying with ASTM D 1187.

G. Non-shrink Grout: As specified in Section 03605, Non-Shrink Grout.

H. Concrete: Comply with requirements in Division 3 Section "Cast-in-Place Concrete" for normal-weight, air-entrained, concrete with a minimum 28-day compressive strength of 3000 psi.

2.6 FABRICATION, GENERAL

A. Shop Assembly: Preassemble items in the shop to greatest extent possible. Disassemble units only as necessary for shipping and handling limitations. Use connections that maintain structural value of joined pieces. Clearly mark units for reassembly and coordinated installation.

B. Cut, drill, and punch metals cleanly and accurately. Remove burrs and ease edges to a radius of approximately 1/32 inch unless otherwise indicated. Remove sharp or rough areas on exposed surfaces.

C. Form bent-metal corners to smallest radius possible without causing grain separation or otherwise impairing work.

D. Form exposed work with accurate angles and surfaces and straight edges.

E. Weld corners and seams continuously to comply with the following:

1. Use materials and methods that minimize distortion and develop strength and corrosion resistance of base metals.


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2. Obtain fusion without undercut or overlap.

3. Remove welding flux immediately.

4. At exposed connections, finish exposed welds and surfaces smooth and blended so no roughness shows after finishing and contour of welded surface matches that of adjacent surface.

F. Form exposed connections with hairline joints, flush and smooth, using concealed fasteners or welds where possible. Where exposed fasteners are required, use Phillips flat-head (countersunk) fasteners unless otherwise indicated. Locate joints where least conspicuous.

G. Fabricate seams and other connections that will be exposed to weather in a manner to exclude water. Provide weep holes where water may accumulate.

H. Cut, reinforce, drill, and tap metal fabrications as indicated to receive finish hardware, screws, and similar items.

I. Provide for anchorage of type indicated; coordinate with supporting structure. Space anchoring devices to secure metal fabrications rigidly in place and to support indicated loads.

1. Where units are indicated to be cast into concrete or built into masonry, equip with integrally welded steel strap anchors, 1/8 by 1-1/2 inches, with a minimum 6-inch embedment and 2-inch hook, not less than 8 inches from ends and corners of units and 24 inches o.c., unless otherwise indicated.

2.7 MISCELLANEOUS FRAMING AND SUPPORTS

A. General: Provide steel framing and supports not specified in other Sections as needed to complete the Work.

B. Fabricate units from steel shapes, plates, and bars of welded construction unless otherwise indicated. Fabricate to sizes, shapes, and profiles indicated and as necessary to receive adjacent construction.

1. Fabricate units from slotted channel framing where indicated.

2. Furnish inserts for units installed after concrete is placed.

C. Fabricate supports for operable partitions from continuous steel beams of sizes indicated with attached bearing plates, anchors, and braces as indicated. Drill or punch bottom flanges of beams to receive partition track hanger rods; locate holes where indicated on operable partition Shop Drawings.

D. Fabricate steel girders for wood frame construction from continuous steel shapes of sizes indicated.

1. Provide bearing plates welded to beams where indicated.

2. Drill or punch girders and plates for field-bolted connections where indicated.

3. Where wood nailers are attached to girders with bolts or lag screws, drill or punch holes at 24 inches o.c.

E. Fabricate steel pipe columns for supporting wood frame construction from steel pipe with steel baseplates and top plates as indicated. Drill or punch baseplates and top plates for anchor and connection bolts and weld to pipe with fillet welds all around. Make welds the same size as pipe wall thickness unless otherwise indicated.


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1. Unless otherwise indicated, fabricate from Schedule 40 steel pipe.

2. Unless otherwise indicated, provide 1/2-inch baseplates with four 5/8-inch anchor bolts and 1/4-inch top plates.

F. Galvanize miscellaneous framing and supports where indicated.

G. Prime miscellaneous framing and supports with primer specified in Specification Section 09928 – Protective Coating Systems where indicated.

2.8 MISCELLANEOUS STEEL TRIM

A. Unless otherwise indicated, fabricate units from steel shapes, plates, and bars of profiles shown with continuously welded joints and smooth exposed edges. Miter corners and use concealed field splices where possible.

B. Provide cutouts, fittings, and anchorages as needed to coordinate assembly and installation with other work.

1. Provide with integrally welded steel strap anchors for embedding in concrete or masonry construction.

C. Galvanize exterior miscellaneous steel trim.

D. Prime exterior miscellaneous steel trim with primer specified in Specification Section 09928, Protective Coating Systems.

2.9 METAL BOLLARDS, GATES, AND POSTS

A. Fabricate metal bollards, gates, and posts from Schedule 80 steel pipe.

1. Cap bollards with 1/4-inch- thick steel plate.

B. Prime bollards, gates, and posts with primer specified in Specification Section 09928 - Protective Coating Systems.

2.10 LOOSE BEARING AND LEVELING PLATES

A. Provide loose bearing and leveling plates for steel items bearing on masonry or concrete construction. Drill plates to receive anchor bolts and for grouting.

B. Galvanize plates.

C. Prime plates with primer specified in Specification Section 09928 – Protective Coating Systems.

2.11 STEEL WELD PLATES AND ANGLES

A. Provide steel weld plates and angles not specified in other Sections, for items supported from concrete construction as needed to complete the Work. Provide each unit with no fewer than two integrally welded steel strap anchors for embedding in concrete.

2.12 FINISHES, GENERAL

A. Comply with NAAMM's "Metal Finishes Manual for Architectural and Metal Products" for recommendations for applying and designating finishes.

B. Finish metal fabrications after assembly.


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C. Finish exposed surfaces to remove tool and die marks and stretch lines, and to blend into surrounding surface.

2.13 STEEL AND IRON FINISHES

A. Galvanizing: Hot-dip galvanize items as indicated to comply with ASTM A 153/A 153M for steel and iron hardware and with ASTM A 123/A 123M for other steel and iron products.

1. Do not quench or apply post galvanizing treatments that might interfere with paint adhesion.

B. Shop prime iron and steel items not indicated to be galvanized unless they are to be embedded in concrete, sprayed-on fireproofing, or masonry, or unless otherwise indicated.

1. Shop prime with primers specified in Specification Section 09928 – Protective Coating Systems.

C. Preparation for Shop Priming: Prepare surfaces in accordance with Specification Section 09928 – Protective Coating Systems.

D. Shop Priming: Apply shop primer to comply with SSPC-PA 1, "Paint Application Specification No. 1: Shop, Field, and Maintenance Painting of Steel," for shop painting.

1. Stripe paint corners, crevices, bolts, welds, and sharp edges.

2.14 ALUMINUM FINISHES

A. Finish designations prefixed by AA comply with the system established by the Aluminum Association for designating aluminum finishes.

B. As-Fabricated Finish: AA-M10 (Mechanical Finish: as fabricated, unspecified). Class I, Clear Anodic Finish: AA-M12C22A41 (Mechanical Finish: nonspecular as fabricated; Chemical Finish: etched, medium matte; Anodic Coating: Architectural Class I, clear coating 0.018 mm or thicker) complying with AAMA 611.

PART 3 EXECUTION

3.1 INSTALLATION, GENERAL

A. Cutting, Fitting, and Placement: Perform cutting, drilling, and fitting required for installing metal fabrications. Set metal fabrications accurately in location, alignment, and elevation; with edges and surfaces level, plumb, true, and free of rack; and measured from established lines and levels.

B. Fit exposed connections accurately together to form hairline joints. Weld connections that are not to be left as exposed joints but cannot be shop welded because of shipping size limitations. Do not weld, cut, or abrade surfaces of exterior units that have been hot-dip galvanized after fabrication and are for bolted or screwed field connections.

C. Field Welding: Comply with the following requirements:

1. Use materials and methods that minimize distortion and develop strength and corrosion resistance of base metals.

2. Obtain fusion without undercut or overlap.

3. Remove welding flux immediately.


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4. At exposed connections, finish exposed welds and surfaces smooth and blended so no roughness shows after finishing and contour of welded surface matches that of adjacent surface.

D. Fastening to In-Place Construction: Provide anchorage devices and fasteners where metal fabrications are required to be fastened to in-place construction. Provide threaded fasteners for use with concrete and masonry inserts, toggle bolts, through bolts, lag screws, wood screws, and other connectors.

E. Provide temporary bracing or anchors in formwork for items that are to be built into concrete, masonry, or similar construction.

F. Corrosion Protection: Coat concealed surfaces of aluminum that will come into contact with grout, concrete, masonry, wood, or dissimilar metals with the following:

1. Cast Aluminum: Heavy coat of bituminous paint.

2. Extruded Aluminum: Two coats of clear lacquer.

3.2 INSTALLING MISCELLANEOUS FRAMING AND SUPPORTS

A. General: Install framing and supports to comply with requirements of items being supported, including manufacturers' written instructions and requirements indicated on Shop Drawings.

B. Anchor supports for operable partitions securely to and rigidly brace from building structure.

C. Support steel girders on solid grouted masonry, concrete, or steel pipe columns. Secure girders with anchor bolts embedded in grouted masonry or concrete or with bolts through top plates of pipe columns.

1. Where grout space under bearing plates is indicated for girders supported on concrete or masonry, install as specified in "Installing Bearing and Leveling Plates" Article.

D. Install pipe columns on concrete footings with grouted baseplates. Position and grout column baseplates as specified in "Installing Bearing and Leveling Plates" Article.

1. Grout baseplates of columns supporting steel girders after girders are installed and leveled.

3.3 INSTALLING METAL BOLLARDS AND POSTS

A. Fill metal-capped bollards and posts solidly with concrete and allow concrete to cure seven days before installing.

1. Do not fill removable bollards with concrete.

B. Anchor bollards to existing construction with expansion anchors, anchor bolts, or through bolts. Provide four 3/4-inch bolts at each bollard unless otherwise indicated.

1. Embed anchor bolts at least 4 inches in concrete.

C. Anchor bollards and posts in concrete in formed or core-drilled holes not less than 8 inches deep and 3/4 inch larger than OD of bollard. Fill annular space around bollard solidly with non-shrink, non-metallic grout; mixed and placed to comply with grout manufacturer's written instructions. Slope grout up approximately 1/8 inch toward bollard.


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D. Anchor bollards and posts in place with concrete footings. Center and align bollards in holes 3 inches above bottom of excavation. Place concrete and vibrate or tamp for consolidation. Support and brace bollards in position until concrete has cured.

E. Anchor internal sleeves for removable bollards in formed or core-drilled holes not less than 8 inches deep and 3/4 inch larger than OD of sleeve. Fill annular space around internal sleeves solidly with non-shrink, nonmetallic grout; mixed and placed to comply with grout manufacturer's written instructions. Slope grout up approximately 1/8 inch toward internal sleeve.

F. Anchor internal sleeves for removable bollards in place with concrete footings. Center and align sleeves in holes 3 inches above bottom of excavation. Place concrete and vibrate or tamp for consolidation. Support and brace sleeves in position until concrete has cured.

G. Place removable bollards over internal sleeves and secure with 3/4-inch machine bolts and nuts. After tightening nuts, drill holes in bolts for inserting padlocks. Owner will furnish padlocks.

H. Fill bollards and posts solidly with concrete, mounding top surface to shed water.

1. Do not fill removable bollards with concrete.

3.4 INSTALLING BEARING AND LEVELING PLATES

A. Clean concrete and masonry bearing surfaces of bond-reducing materials, and roughen to improve bond to surfaces. Clean bottom surface of plates.

B. Set bearing and leveling plates on wedges, shims, or leveling nuts. After bearing members have been positioned and plumbed, tighten anchor bolts. Do not remove wedges or shims but, if protruding, cut off flush with edge of bearing plate before packing with grout.

1. Use non-shrink grout, either metallic or nonmetallic, in concealed locations where not exposed to moisture; use non-shrink, nonmetallic grout in exposed locations unless otherwise indicated.

2. Pack grout solidly between bearing surfaces and plates to ensure that no voids remain.

3.5 ADJUSTING AND CLEANING

A. Touchup Painting: Immediately after erection, clean field welds, bolted connections, and abraded areas. Paint uncoated and abraded areas with the same material as used for shop painting to comply with SSPC-PA 1 for touching up shop-painted surfaces.

1. Apply by brush or spray to provide a minimum 2.0-mil dry film thickness.

B. Touchup Painting: Cleaning and touchup painting of field welds, bolted connections, and abraded areas of shop paint are specified in Section 09928 – Protective Coating Systems.

C. Galvanized Surfaces: Clean field welds, bolted connections, and abraded areas and repair galvanizing to comply with ASTM A 780.

END OF SECTION


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MISCELLANEOUS METALS 05510-1

SECTION 05510

MISCELLANEOUS METALS

PART 1 - GENERAL

1.1 SUBMITTALS

Submit the following information for review. Do not begin fabrication until after submittals have been reviewed.

A. Shop Drawings.

1. Submit shop drawings on all fabricated and cast items. Indicate thickness, type, grade, class and finish of metal. Show construction details, reinforcement, anchorage interface relation with adjacent construction, and mark numbers. For members to be shop primed, show surface preparation and brand name and manufacturer's number designation of primer proposed for use.

2. The use of reproductions of the contract drawings by any contractor, subcontractor, erector, fabricator or material supplier in lieu of preparation of shop drawings signifies his acceptance of all information shown thereon as correct, and obligates himself to any job expense, real or implied, arising due to any errors that may occur thereon. In addition, all references to the engineering firm(s) that prepared the Contract Documents, including professional seals, must be removed if reproductions of the contract drawings are used as shop drawings.

B. Manufacturer's Product Data. Manufacturer's product data shall contain sufficient information to evaluate conformance to specifications and produce suitability for intended use. Submit test reports from accredited independent testing laboratories where specified. Submit manufacturer's product data for the following products:

1. Expansion Anchors. Certified pullout and shear capacities shall be included in the submittal.

2. Standard cast products.

C. Welding Procedure. Submit written description as required to illustrate each welding procedure for welds that are not prequalified per AWS D1.1, Structural Welding Code - Steel.

1.2 SUBSTITUTIONS

Substitution of rolled sections, details or products is not permitted without prior written approval. If items shown or specified are not readily obtainable, permission to substitute for the specified item may be requested by the Contractor. Substitutions may be allowed on items of equal or superior properties which conform to design criteria.

1.3 GAUGES

U.S. standard for sheet and plate.

1.4 QUALIFICATION OF WELDERS

Welding must be performed by certified welders. Steel welders must be qualified by procedures of AWS D1.1, Structural Welding Code - Steel, using procedures, materials and equipment of the type required for the work.


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Design of steel fabrications shall conform to the requirements of AISC Specifications for Structural Steel for Building, Allowable Stress Design (Fourteenth Edition).

1.6 INSPECTION AND TESTING

The materials and workmanship covered in this specification may be inspected by the Owner, the Engineer or the Owner's designated testing laboratory. The testing laboratory will be employed and paid by the Owner as specified in Section 01380 – Quality Control. Inspection may be performed in the mill, shop or field as deemed necessary. Inspection in no way relieves the Contractor from his responsibility to furnish satisfactory materials. The right to reject material at any time before final acceptance is reserved, if material and workmanship do not conform to drawings and specifications.

1.7 FIELD MEASUREMENTS

Prior to fabrication, take necessary field measurements of previously installed construction so that work will fit properly. Members that do not fit properly must be replaced unless approval for their modification has been obtained from the Engineer.


Schedule material delivery so that items may be erected promptly after arrival. If materials must be stored at the project site, they shall be stored aboveground on platforms, skids or other supports. Material stored at the site shall be kept free of dirt, mud, grease or oil. Protect stored material from corrosion.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Carbon Steel Shapes, Plates and Bars.

1. Steel shapes and bars shall conform to ASTM A36 unless otherwise specified or noted on the drawings.

2. Steel plate, including plate to be bent or formed cold, shall conform to ASTM A36 with a minimum yield strength of 36,000 psi except that plate conforming to ASTM A283, Grade C, may be used at steel strap anchors.

3. Use carbon steel except where otherwise specified or noted on the drawings.

B. Steel Pipe. Conform to ASTM A53, Type E or S, Grade B, welded or seamless. No hydrostatic tests are required.

C. Steel Tubing. Conform to ASTM A500, Grade B.

D. Stainless Steel. Where indicated on the drawings as "stainless steel," "stn. steel" or "SS," use stainless steel of the type shown. Where the type is not shown, use stainless steel Type 316 for non-welded items and Type 316/316L dual certified for welded items. Stainless steel shall conform to the following requirements:

1. Plate, Sheet and Strip. ASTM A167.

2. Bars and Shapes. ASTM A276.

3. Finish shall conform to ASTM A480 as follows:

a. Sheet - No. 1 finish.


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b. Strip - No. 1 finish.

c. Plate - hot-rolled and annealed or heat treated, and blast cleaned or pickled.

E. Galvanized Sheet Steel. Conform to ASTM A526, commercial quality hot-dipped zinc-coated sheets fabricated of commercial quality cold-rolled steel, coating designation G90, mill phosphatized, not oiled.

F. Paint for Shop Primer.

1. Section 09928 – Protective Coatings Systems.

G. Galvanizing Repair Coating. Hot-applied zinc-based solder conforming to the requirements of ASTM A780.

2.2 MISCELLANEOUS METAL ITEMS

A. Miscellaneous metal items listed herein are typical for this section. Refer to Drawings for additional items not listed herein.

B. Miscellaneous Framing and Supports.

1. Provide miscellaneous steel framing and supports which are not a part of structural system and not shown on structural drawings.

2. Fabricate miscellaneous units to sizes, shapes and profiles shown or, if not shown, of required dimensions to receive adjacent other work to be retained by framing. Except as otherwise shown, fabricate from steel units to receive hardware and similar items.

3. Provide bolts, screws and other fastenings as required to connect steel to other materials.

2.3 FABRICATION

A. General Fabrication Requirements.

1. Assembly. Where practical, fit and assemble items in the shop and deliver to the site ready for installation.

2. Use materials of the size and thicknesses shown or, if not shown, of the required size and thickness to produce adequate strength and durability in the finished product for the intended use. Work to the dimensions shown or in accordance with job measurements. Use type of materials shown or specified for the various components of the work.

3. Form exposed work true to line and level with accurate angles and surfaces and sharp, straight edges. Ease exposed edges to a radius of approximately 1/32 inch. Form bent metal corners to the smallest radius possible without causing grain separation or otherwise impairing the work.

4. Joints exposed to the weather shall be formed to exclude water. All joints shall be flush and smooth.

5. All shop connections shall be welded except where welding is not practical or unless shown otherwise on the drawings. Where screws or bolts cannot be avoided, conceal fasteners where possible or countersink heads, screw up tight and nick threads to prevent loosening.


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6. Weld joints continuously except where skip welding is permitted as shown on the drawings. In all lapped or "tee" splices or other joints where intermittent filler welds are allowed, the edges of faying surfaces shall be continuously seal welded in accordance with the required strength weld. Grind exposed welds smooth and flush to match and blend with adjoining surfaces.

7. Welding process and procedures shall be the most suitable process for the connection as selected by the Contractor and approved by the Engineer. The Contractor's propose welding process shall be shown on the shop drawings. All shop and field welding must be performed by qualified welders who hold current welding certificates.

8. Provide for anchorage of the type shown or as required, coordinated with the supporting structure. Fabricate and space anchoring devices as shown and as required to provide adequate support of the work.

9. Cut, reinforce, drill and tap miscellaneous metal work as may be required to receive other items of work.

10. Where possible, all cuts shall be cut or flame-cut with automatic guided equipment. Any edges requiring cutting with a handheld torch shall be ground neat, smooth and straight. Edges shall be ground free of sharp edges, burrs and weld splatters. All fits shall be accurate and neat.

11. Re-entrant corners shall be free of notches or sharp corners. Provide a 1-inch radius unless noted otherwise on the drawings.

12. Bolt holes shall be punched and drilled, or sub-punched and reamed. If holes are flame-cut, they shall be burned undersize and reamed to correct size.

B. Steel Fabrication.

1. Fabrication of steel items shall conform to AISC Code of Standard Practice for Steel Buildings and Bridges.

2. Welding shall conform to the requirements of AWS D1.1, Structural Welding Code - Steel. Welding not governed by the above shall be performed in accordance with best modern practice for strength and durability.

3. Construct steel frames for approved fire doors according to the requirements of authority having jurisdiction for class of opening indicated or specified. Frames which bear Underwriter Laboratories' label for class of opening required will be basis of acceptance. Authorized construction details and requirements for approved fire door frames take precedence over project details or specifications, except where thicker gauges than those required for approval are specified.

4. Loose lintels shall have a minimum bearing of 8 inches on each end unless shown otherwise. All lintels shall be hot-dip galvanized.

C. Stainless Steel Fabrication. Carbon steel tools or lifting devices shall not come in direct contact with items being fabricated of stainless steel. Should carbon steel inadvertently come in contact with the stainless steel, the stainless steel must be cleaned of any embedded carbon steel particles. All heat tint from welding operations shall be removed.

D. Aluminum Fabrication.

1. Fabrication of aluminum items shall conform to the Aluminum Association's "Specifications for Aluminum Structures."


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2. Welding shall conform to the requirements of AWS D1.2, Structural Welding Code - Aluminum. Welding not governed by the above shall be performed in accordance with best modern practice for strength and durability. When possible, all welding shall be done in the shop.

3. All aluminum surfaces shall have a mill finish free from die markings, scratches, welding discolorations, or other surface blemishes.

4. Aluminum surfaces that will be in contact with concrete or steel shall be given a heavy coat of alkali-resistant bituminous paint, or other coating recommended by the manufacturer that will provide equivalent protection. The coating shall not be visible in the completed installation.

2.4 GALVANIZING

A. All carbon steel items shown on the drawings to be galvanized or specified to be galvanized shall be galvanized after fabrication. Galvanize in accordance with ASTM A123 or ASTM A153 as applicable.

B. The Contractor shall safeguard against warpage and distortion during hot-dip galvanizing as specified in ASTM A384. Any member or assembly that is warped or distorted must be straightened. Any member or assembly that cannot be straightened must be replaced at no additional cost to the Owner.

2.5 SHOP PRIME

A. Shop prime all carbon steel members or assemblies that are not shown or specified to be galvanized or that are not encased in concrete. Stainless steel and aluminum items shall not be shop primed. Before assembly, paint surfaces that will be inaccessible after fabrication. Primer shall be applied in accordance with the paint manufacturer's recommendations and instructions. Surface preparation shall produce the profile recommended by the paint manufacturer.

B. Shop Prime Schedule.

1. Exposed Steel

a. Surface Preparation. Per Section 09928.

b. Paint. Primer suitable for use with paint system for the application intended as specified in Section 09928.

c. Minimum Thickness. Per Section 09928.

2. Submerged Steel.

a. Surface Preparation. Per Section 09928.

b. Paint. Primer suitable for use with epoxy paint system for immersion in potable water applications.

c. Minimum Thickness. Per Section 09928

2.6 PROTECTIVE COATINGS FOR ALUMINUM GRATING SUPPORTS

The top of steel support beams and seats for aluminum grating shall be coated with a heavy coat of alkali-resistant bituminous paint or similar coating to prevent contact between the steel and the aluminum grating.


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PART 3 - EXECUTION

3.1 CONDITION OF SURFACES

A. Prior to installation, inspect surfaces to which miscellaneous metal items will be attached. If the condition of the surface is such that it will adversely affect installation, do not proceed with installation until corrective measures have been taken.

B. Verify that aluminum surfaces that will be in contact with concrete or steel have been coated as specified.

3.2 INSTALLATION

A. Accurately set work to established lines and elevations and securely fasten in accordance with approved shop drawings and provisions of this section.

B. The Contractor shall be fully responsible for furnishing and installing any temporary braces, ties or shoring necessary to hold secure and safe all items under the action of wind and erection loads imposed thereon until construction is completed.

3.3 WELDING

A. Welding Steel. Conform to requirements of AWS D1.1, Structural Welding Code - Steel.

B. Welding Aluminum. Conform to requirements of AWS D1.2, Structural Welding Code - Aluminum.

3.4 ERECTION OF STEEL ITEMS

Erection of steel items must conform to AISC specification, Structural Steel for Buildings. Field-fabricated bolt holes, when required, shall be drilled; or as an alternate, they may be flame-cut undersize and reamed to correct size.

3.5 GROUTING

Grout for base plates, etc., shall be as specified in Section 03605 – Non-Shrink Grout.

3.6 COATING REPAIRS

Thoroughly clean field welds, abrasions, and damaged or defective areas of shop-primed or galvanized surfaces.

A. Painted Surfaces. Prepare the surface as previously specified for shop painting. After the surface is prepared, apply a heavy coat of matching shop paint.

B. Galvanized Surfaces. Prepare the damaged surface and apply a minimum of 2 mils of the specified galvanized repair coating in conformance with the requirements of ASTM A780. Where the repair coating manufacturer's recommendations are more stringent than ASTM A780, the manufacturer's recommendations shall be followed.

3.7 FIELD PAINTING

Field painting shall conform to the following. Where practical, final coats may be applied in the shop.

A. Steel in Buildings. Paint system as specified in Section 09928 – Protective Coatings Systems.

B. Steel Exposed to Weather. Epoxy-polyurethane paint system as specified in Section 09928 – Protective Coatings Systems.


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C. All Submerged Carbon Steel. Epoxy paint system suitable for potable water applications as specified in Section 09928 – Protective Coatings Systems.

D. Galvanized Surfaces. Galvanized surfaces to be painted shall receive an epoxy-polyurethane coating system as specified in Section 09928 – Protective Coatings Systems.

3.8 PROTECTION OF ERECTED MISCELLANEOUS METAL ITEMS

A. After erection, the miscellaneous metal items must be protected to prevent damage prior to final acceptance of the project. All items shall be free from scratches, nicks, gouges, dents, concrete splatter, paint splatter or other foreign material. Material damaged in a manner that will affect durability, strength or appearance which cannot be repaired to the satisfaction of the Engineer must be replaced without additional cost to the Owner.

B. Stainless steel items shall be cleaned of all rust spots caused by carbon steel embedded particles where carbon steel items have come in contact with the stainless steel. All carbon steel embedded particles shall be removed to prevent further rust spots from forming.

END OF SECTION


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BLANK PAGE


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BOLTS, ANCHOR BOLTS, EXPANSION ANCHORS, AND CONCRETE INSERTS 05550-1

SECTION 05550

BOLTS, ANCHOR BOLTS, EXPANSION ANCHORS,

AND CONCRETE INSERTS

PART 1 - GENERAL

1.1 SUBMITTALS

Submit the following information for review. Do not begin fabrication until after submittals have been reviewed.

A. Manufacturer's Product Data. Manufacturer's product data shall contain sufficient information to evaluate conformance to specifications and produce suitability for intended use. Submit test reports from accredited independent testing laboratories where specified. Submit manufacturer's product data for the following products:

1. Expansion Anchors. Certified pullout and shear capacities shall be included in the submittal.

2. Standard cast products.

1.2 SUBSTITUTIONS

Substitution of rolled sections, details or products is not permitted without prior written approval. If items shown or specified are not readily obtainable, permission to substitute for the specified item may be requested by the Contractor. Substitutions may be allowed on items of equal or superior properties which conform to design criteria.


Design of steel fabrications shall conform to the requirements of AISC Specifications for Structural Steel for Building, Allowable Stress Design (Current Edition).


The materials and workmanship covered in this specification may be inspected by the Owner, the Engineer or the Owner's designated testing laboratory. The testing laboratory will be employed and paid by the Owner as specified in Section 01380 – Quality Control. Inspection may be performed in the mill, shop or field as deemed necessary. Inspection in no way relieves the Contractor from his responsibility to furnish satisfactory materials. The right to reject material at any time before final acceptance is reserved, if material and workmanship do not conform to drawings and specifications.


Schedule material delivery so that items may be erected promptly after arrival. If materials must be stored at the project site, they shall be stored aboveground on platforms, skids or other supports. Material stored at the site shall be kept free of dirt, mud, grease or oil. Protect stored material from corrosion.


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PART 2 - PRODUCTS

2.1 MATERIALS

A. Bolts, Studs, Nuts and Washers.

1. Carbon Steel. Conform to ASTM A325, with suitable nuts and washers, as noted on the drawings. Washers bearing on metal shall be cast steel. Where type is not noted on the drawings, provide ASTM A325. Use carbon steel bolts except where indicated otherwise on the drawings.

2. Stainless Steel. Where shown on the Drawings, bolts shall be Type 304 conforming to ASTM A193 Grade B8M, Class 2 or 2B with ASTM A194 Grade 8 stainless steel nuts and washers. Where shown on the Drawings, bolts shall be Type 316 conforming to ASTM A193 Grade B8M, Class 2 with ASTM A194 Grade 8M stainless steel nuts and washers. Use stainless steel bolts where specified or indicated on the drawings as "stainless steel," "SS" or "stn. steel."

3. Corrosion Resistant Steel (CRS) (For Buried Piping Installations). CRS anchor bolts, flange bolts, and studs shall be “Cor-Ten” type steel and shall conform to ASTM A325 Type 3 weathering steel with minimum tensile strength of 105 ksi. Type 3 bolts shall be marked A325. Nuts shall be in conformance with ASTM A563 Grade C3.

4. At buried mechanical joints, bolts and nuts shall be in conformance with all of AWWA C111 dimensions and requirements. Bolts and nuts shall be tension tested for a minimum ultimate tensile stress of 65 ksi using testing procedures corresponding to ASTM A307 requirements, and shall be proof load tested based on 45 ksi stress to AWWA C111 standards.

5. Bolt heads shall be marked with manufacturer, ASTM material designation/grade, and country where manufactured. Markings shall be raised or depressed.

6. At joint harnesses and restrained harnesses connected to flanges, the tie bolts and studs, flange bolts and nuts shall be in conformity with the current ASTM A193, Grade B7 and ASTM A194.

7. For pipe joints, bolt strength shall be adequate to provide compression needed for water tightness of the gasket material used.

B. Anchor Bolts.

1. Carbon steel anchor bolts shall be galvanized threaded rods conforming to ASTM A307, except where shown or specified otherwise, with suitable heavy hex nuts and oversize washers. Anchor bolts and nuts shall be tapped or chased after galvanizing. Use carbon steel anchor bolts except where noted otherwise on the drawings.

2. Stainless steel anchor bolts shall be Type 304 conforming to ASTM A193 Grade B8. Use stainless steel anchor bolts where shown on the drawings as "stainless steel," "stn. steel" or "SS." Provide stainless steel anchor bolts with suitable stainless steel nuts and oversize washers.

3. Provide anchor bolts for all equipment and machinery when anchor bolts are not furnished by the manufacturer. Anchor bolt type, size, length, projection, etc., shall conform to the requirements of the equipment and machinery manufacturer.

4. Provide templates to accurately position the anchor bolts in the forms.


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C. Concrete Expansion Anchors.

1. Provide drilled-in concrete expansion anchors, which are externally threaded edge type expansion bolt anchors complete with washers and nuts. The anchors shall conform to Federal Specification FF-S-325, Group II, Type 4, Class 1 concrete expansion anchors.

2. Carbon Steel Expansion Anchors. Not allowed.

3. Stainless Steel Expansion Anchors. Provide stainless steel expansion anchors conforming to AISI Type 316.

4. The expansion anchors shall have minimum ultimate capacity when tested in accordance with ASTM E 488 in 4,000 psi concrete as follows:

Stainless Steel:

Bolt Size 1" 3/4" 5/8" 1/2"

Minimum Shear Strength* 28,000# 18,000# 12,500# 8,340#

Minimum Pullout Strength 27,000# 14,500# 11,000# 8,000#

Minimum Embedment 6" 4-3/4" 4" 3-1/2"

*Shear plane through the anchor bolt shank.

5. Expansion anchors shall be installed in accordance with the manufacturer's recommendations.

6. A list of standard materials used in the manufacturer of the anchor components, including designated material specification (AISI, ASTM, etc.), as well as pullout and shear values attained from tests performed by a certified independent testing laboratory in accordance with ASTM E 488, shall be submitted to the Engineer for review. The submittal shall also include the manufacturer's installation instructions.

PART 3 - EXECUTION

3.1 CONDITION OF SURFACES

A. Prior to installation, inspect surfaces to which miscellaneous metal items will be attached. If the condition of the surface is such that it will adversely affect installation, do not proceed with installation until corrective measures have been taken.

B. Verify that aluminum surfaces that will be in contact with concrete or steel have been coated as specified

3.2 INSTALLATION

A. Accurately set work to established lines and elevations and securely fasten in accordance with approved shop drawings and provisions of this section.

B. The Contractor shall be fully responsible for furnishing and installing any temporary braces, ties or shoring necessary to hold secure and safe all items under the action of wind and erection loads imposed thereon until construction is completed.

C. Prior to placement of concrete, set concrete inserts (e.g. anchor bolts) in proper location and provide necessary anchorages or restraints to prevent movement of inserts during concrete placement.


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D. For stainless steel bolting, apply anti-sieze compound liberally to bolt threads and face of nuts to prevent galling.

E. Follow manufacturer’s installation instructions for concrete expansion anchors.

3.3 ERECTION OF STEEL ITEMS

A. Erection of steel items must conform to AISC specification, Structural Steel for Buildings. Field-fabricated bolt holes, when required, shall be drilled; or as an alternate, they may be flame-cut undersize and reamed to correct size.

END OF SECTION


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GLASS FIBER AND RESIN FABRICATIONS 06601-1

SECTION 06601

GLASS FIBER AND RESIN FABRICATIONS

PART 1 - GENERAL 1.1 SECTION INCLUDES

A. Fiber Reinforced Plastics (FRP); glass fiber reinforced, vinyl ester resin fabrications.

B. Refer to list of items scheduled at end of Section. 1.2 REFERENCES

A. ASTM A276 - Stainless and Heat-Resisting Steel Bars and Shapes.

B. ASTM D757 - Test Method for Incandescence resistance of Rigid Plastics in Horizontal Position.

C. ASTM E84 - Test Method of Surface Burning Characteristics of Building Materials.

D. ASTM F593 - Stainless Steel Bolts, Hex Cap Screws, and Studs.

E. ASTM F594 - Stainless Steel Nuts.

F. OSHA - Occupational Safety and Health Administration; Code of Federal Regulations, Title 29 - Labor.

G. UL - Underwriters Laboratories. 1.3 SYSTEM DESCRIPTION

A. Minimum mechanical properties except as modified under Part 2:

1. Ultimate Tensile Strength: (longitudinal coupon) 30,000 psi

2. Ultimate Tensile Strength: (transverse coupon) 7,000 psi

3. Ultimate Compressive Strength: (longitudinal coupon) 30,000 psi

4. Ultimate Compressive Strength: (transverse coupon) 15,000 psi

5. Ultimate Shear Strength: 4,500 psi

6. Ultimate Bearing Strength: 30,000 psi

7. Modules of Elasticity: (full section in bending) 2,500,000 psi

8. Barcol Hardness: 45

B. Design Live Loads: 100 lbs/sq ft with deflection limited to 1/240 unless otherwise noted.

C. Design items with sufficient strength for handling stresses.


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D. Ship items in preassembled lengths completely assembled and ready for final field assembly and installation.

E. Clearly identify each piece, part, or unit with a chemical resistant tag, showing manufacturer's certified drawing number, and part number securely fastened to the part with a chemical resistant fastener.


A. Fabricator: Company specializing in architectural glass fiber and resin components with 5 years documented experience.

B. Design assemblies under direct supervision of a Professional Structural Engineer experienced in design of this work registered in the State of Texas.


A. Fire retardant class I- flame spread of 25 in accordance with ASTM E84.

B. Flammability: ASTM D635, maximum average rate of burning 0.08 in./min.

1.6 SUBMITTALS

1.2 Submit shop drawings under provisions of Section 01330 – Submittal Procedures. 1.3 Submit shop drawings indicating design load parameters, dimensions, adjacent

construction, materials, thicknesses, fabrication details, required clearances, field jointing, tolerances, colors, finishes, methods of support, integration of components, and anchorages.

1.4 Submit product data on specified component products. 1.5 Submit samples as required. 1.6 Submit fabricator's installation instructions as required.

1.7 OPERATION AND MAINTENANCE DATA

A. Submit cleaning and maintenance data under provisions of Section 01770 – Closeout Procedures.

B. Include instructions for stain removal, surface and gloss restoration.


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A. Deliver, store and protect products under provisions of Section 01600 – Materials and Equipment.

B. Protect components from damage by retaining shipping protection in place until installation.

1.9 ENVIRONMENTAL REQUIREMENTS

A. Maintain temperature and humidity conditions favorable to proper curing of resin during and after installation.

PART 2 - PRODUCTS 2.1 MATERIALS

A. Glass reinforcement: Three Varieties:

1. A surfacing mat used on all exterior surfaces for maximum chemical resistance. 2. Continuous glass strand rovings internally for longitudinal strength. 3. Continuous strand mats used internally for transverse strength.

B. Roving: Continuous strand reinforcement for continuous impregnation, single end, wound

into tubeless packaging, for vinylester resin.

C. Mat: Chopped fine glass fiber strand, sized into mat form, 9.5 oz/sq yd for vinylester resin laminate reinforcement.

D. Resin: Vinylester type, Class l flame spread and flammability ratings in accordance with ASTM E84, chemical resistant, corrosion resistant, high workability characteristics and integral coloring additives.

E. Gel Coat: Provide a resin gel coat with UV inhibitors for all fiberglass items.

F. Polishing Cream: Compatible gel coat polishing cream to restore gloss surface finish.

2.2 STAIRS

A. Stair Treads:

1. Open grate type 1-1/2-inch thick, 5/8-inch solid nosing, and non-skid surface, bearing on stainless steel clip angles bolted to stringers with stainless steel bolts.

2. Ultimate Tensile Strength: 20,000 psi.

3. Ultimate Compressive Strength: 20,000 psi.

4. Maximum deflection from 400 lbs load at midspan (36-inch x 11-1/2-inch tread) 5/16-inch.


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B. Design Loads:

1. Design stairs for a moving concentrated load of 1000 lbs. minimum in accordance with OSHA, 29 CFR 1910.24. "Fixed industrial stairs", with a safety factor of 3 applied.

2. Stairs shall sustain 100 psf of vertical projected load.

C. Handrail: Install on both sides of all open stairways having 3 or more risers. 2.3 LADDERS

A. Design: In accordance with OSHA, 29 CFR 1910.27, "Fixed ladders".

B. Design Loads: Apply a minimum safety factor of 5 to loads referenced in OSHA, 29 CFR 1910.27.

C. Bond joints, couplings, etc., with epoxy or mechanically fasten with non-metallic hardware, except field splice joints, which utilize Type 304 stainless steel fasteners.

D. Rungs:

1. Reinforce rung and side rail connections with a pin and keyway arrangement to

prevent rotation during climbing.

2. Bond an epoxy/glass bead non-skid coating to upper surfaces of rungs for maximum safety.

3. Clear rung width: 18-inches.

4. Vertical centers: 12-inches.

E. Ladder Cages: Provide FRP cages when required, and always on ladders 20-feet or greater in length.

F. Standoffs: 6-feet vertical centers maximum and 7-inches minimum clear distance to wall. 2.4 GRATING

A. Thickness: 2 inches.

B. Panels shall be manufactured using the "pultrusion" process.

C. Band panels on all sides whenever possible.

D. Bond an epoxy/glass bead non-skid coating to upper surfaces for maximum safety.

E. Hold down clamps and bolts: Type 316 stainless steel, at 4-foot centers in each direction.

F. Mechanical Properties:

1. Ultimate Tensile Strength: 25,000 psi

2. Ultimate Compressive Strength: 25,000 psi


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3. Modules of Elasticity: 1,500,000 psi

4. Weight per Square Foot: 3.70 lbs.

5. Density: 29 lb/ s.f.

6. Open Area: 50 percent

G. Design Loads and Deflection:

1. Maintain a 1 percent deflection (max) and a 10 to 1 factor of safety due to a 1000 pound concentrated load distributed over a 2.5 foot-square area at midspan.

2. Maintain a 1 percent deflection (max) and a 10 to 1 factor of safety due to 100 pound per square foot uniformly distributed loads.

2.5 HANDRAILS

A. Furnish the handrail system complete including all necessary bolting, epoxy, plastic fasteners, and base plates, as specified and required. It is the specific intent of this requirement to provide a complete system from one source, without further responsibility.

B. Furnish handrail complete with 4-inch toe board, when required, as specified in referenced OSHA document. Provide three horizontal rails with the top rail located 42 inches above the adjacent walking surface. The toe board shall be located 1/4 inch above the walking surface and the rails shall be spaced such that a 12-inch diameter sphere cannot pass between them. Omit toe boards at stairways.

C. Design Requirements: OSHA, 29 CFR 1910.21, "Definitions" and OSHA, 29 CFR 1910.23 "Guarding floor and wall openings and holes".

D. Apply a minimum safety factor of 5 to loads referenced in OSHA.

E. Bond all joints, couplings, etc., with epoxy, and pin for additional safety.

F. Posts: Mounted at 6-feet on center maximum spacing.

G. Shop machine corners and splices free of posts and ready for field assembly.

H. Deform toe boards in such a manner as to provide both horizontal and vertical stiffness, without sag, and shall run true with the guardrail. Toe boards shall be connected to each railing post with a minimum of two fasteners in horizontal slotted holes. Splices shall be located and detailed to allow for thermal expansion and contraction.

2.6 ACCESSORIES

A. Hardware: ASTM A276 stainless steel type 316.

B. Field joints: Bolted connections unless otherwise specified. All fasteners shall be bolts per ASTM F593, Type 316 and nuts per ASTM F594, Type 316; unless indicated otherwise.

2.7 FABRICATION


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A. Mold Material: Metal FRP type.

B. Mold Surface: Smooth.

C. Structural FRP Members: Manufactured using the "pultrusion" process, consisting of a glass fiber reinforced vinylester resin matrix approximately 50 percent resin to glass ratio by volume and 50 percent to 70 percent glass by weight.

D. Finish other surfaces not in contact with the mold to match the molded surfaces in appearance.

E. Finish trim corners and edges.

F. Coat exposed surface and surfaces in contact with moisture or earth with gel coat of colored resin.

G. Cure components prior to shipment and remove materials which contain fiber blemish, pinholes and dry spots or which may be incompatible with adjacent building materials.

H. Seal all cut edges and holes with a compatible resin system.

I. Coat surfaces with a polyurethane coating to prevent ultraviolet surface degradation.

PART 3 - EXECUTION 3.1 EXAMINATION

A. Verify that surfaces are ready to receive work and dimensions are as indicated on shop drawings.

B. Beginning of installation means acceptance of existing surfaces.

3.2 INSTALLATION

A. Install fabrications in accordance with Drawings and fabricator's instructions.

B. Reseal all cut edges with a pigmented compatible resin system.

C. Shop prepare all surfaces to be field epoxy bonded.

D. Install all components square and true, without warp, twist, sag, or buckle.

E. Epoxy bond and mechanically fasten all field joints using non-metallic hardware.

3.3 TOLERANCES

A. Maximum Variation from True Position: 1/4 inch.

B. Maximum Offset from True Alignment: 1/8 inch.


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3.4 CLEANING

A. Clean components of foreign material.

B. Clean fabrications in accordance with fabricator's instructions.

3.5 PROTECTION

A. Protect finished installation under provisions of Section 01500 – Construction Facilities and Temporary Controls.

3.6 SCHEDULE

A. Structural Framing: As detailed, dull grey in color, gloss surface finish.

B. Stairs: As detailed, dull grey in color, non-skid surface.

C. Ladders: As detailed, solid safety yellow color throughout, gloss surface finish.

D. Grating: As detailed, solid safety yellow color throughout, gloss surface finish.

E. Handrail: As detailed, solid safety yellow color throughout, gloss surface finish.

END OF SECTION


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DAMPPROOFING AND WATERPROOFING 07115-1

SECTION 07115

DAMPPROOFING AND WATERPROOFING

PART 1 - GENERAL

1.1 WORK INCLUDES

A. Hot-applied asphalt dampproofing, exterior surfaces of below grade concrete walls.

B. Cold-applied, cut-back asphalt dampproofing, exterior surfaces of below grade concrete walls.

C. Cold-applied, asphalt emulsion dampproofing, exterior surfaces of below grade concrete walls.

D. Cementitious slurry capillary (crystalline) waterproofing, exterior exposed-to-view surfaces of concrete walls.


A. ASTM C 109: Standard Test Method for Compressive Strength of Hydraulic Cement Mortars (use 2 in (50 mm) Cube Specimens.

B. ASTM C 321: Standard Test Method for Bond Strength of Chemical-Resistant Mortars.

C. ASTM C 348: Standard Test Method for Flexural Strength of Hydraulic Cement Mortars.

D. ASTM C 596: Standard Test Method for Drying Shrinkage of Mortar Containing Portland Cement.

E. ASTM C 944: Standard Test Method for Abrasion Resistance of Concrete or Mortar Surfaces by the Rotating-Cutter Method.

F. ASTM D41: Asphalt Primer Used in Roofing, Dampproofing and Waterproofing.

G. ASTM D43: Creosote Primer Used in Roofing, Dampproofing, and Waterproofing.

H. ASTM D449: Asphalt Used in Dampproofing and Waterproofing.

I. ASTM D450: Coal-Tar Pitch Used in Roofing, Dampproofing, and Waterproofing.

J. ASTM D491: Asphalt Mastic Used in Waterproofing.

K. ASTM D2822: Asphalt Roof Cement.

L. ASTM D4022: Coal Tar Roof Cement.

M. COE CRD-C 48: Method of Test for Water Permeability of Concrete; US Army Corps of Engineers.

N. NRCA Waterproofing Manual - National Roofing Contractors Association

O. NSF/ANSI Standard 61: Drinking Water System Components – Health Effects (for use of waterproofing material on structures holding potable water).

1.3 SUBMITTALS



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B. Product Data: Provide data for each type of product specified, including data substantiating that materials comply with requirements for each dampproofing material specified. Include recommended method of application, recommended primer, number of coats, coverage and thickness, and recommended protection course.

C. Manufacturer's Installation Instructions: Indicate special procedures and perimeter conditions requiring special attention.

D. Dampproofing manufacturer shall provide Certification that products supplied comply with local regulations controlling use of volatile organic compounds (VOCs).


A. Installer Qualifications: Installer who has completed bituminous dampproofing similar in material, design, and extent to that indicated for this Project and with a documented 5-year minimum record of successful in-service performance.

B. Work required in conjunction with the cementitious slurry capillary waterproofing shall be conducted by an organization which specializes in waterproofing.

C. Single-Source Responsibility: Primary dampproofing materials and primers shall be supplied from one source and by a single manufacturer. Provide secondary materials only as recommended by manufacturer of primary materials.

D. Perform Work in accordance with NRCA Waterproofing Manual.


A. Substrate: Proceed with dampproofing only after substrate construction and penetrating work have been completed.

B. Weather Limitations: Proceed with dampproofing only when existing and forecasted weather conditions will permit work to be performed according to manufacturer's recommendations and warranty requirements.

C. Ventilation: Provide adequate ventilation during application of dampproofing in enclosed spaces. Maintain ventilation until dampproofing had thoroughly cured.

PART 2 - PRODUCTS

2.1 ACCEPTABLE MANUFACTURERS

A. Hot-Applied Asphalt Dampproofing.

1. W. R. Meadows, Inc.

2. Owens-Corning Fiberglas Corp.

3. Or approved alternative.

B. Cold-Applied, Cut-Back Asphalt Dampproofing.

1. ChemRex, Inc; Sonneborn Building Products Division

2. Karnak Chemical Corporation




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C. Cold-Applied, Asphalt Emulsion Dampproofing.

1. ChemRex, Inc. - Sonneborn Building Products Division

2. Euclid Chemical Company

3. Karnak Chemical Corporation

4. Koppers Industries, Inc.



D. Cementitious Slurry Capillary (Crystalline) Waterproofing.

1. Xypex Chemical Corporation

2. Vandex (USA), Inc.

3. W.R. Meadows, Inc.

4. Aquafin, Inc.


2.2 BITUMINOUS DAMPPROOFING

A. Hot-Applied Asphalt Dampproofing: Comply with ASTM D 449, Type I.

B. Cold-Applied, Cut-Back Asphalt Dampproofing: Asphalt and solvent compound mixed to a smooth, uniform consistency to provide a firm, moisture-resistant, vapor-resistant, elastic coating recommended by the manufacturer for dampproofing use when applied according to the manufacturer's instructions.

1. Semimastic Grade: Asphalt roof coating, consisting of an asphalt base with petroleum solvents and mineral stabilizers, complying with ASTM D 4479, Type I.

2. Spray Grade: Asphalt roof coating, consisting of an asphalt base with petroleum solvents and no mineral fibers, complying with ASTM D 4479, Type I.

C. Cold-Applied, Asphalt Emulsion Dampproofing: Asphalt-based emulsions recommended by the manufacturer for dampproofing use when applied according to the manufacturer's instructions.

1. Semimastic Grade: Emulsified asphalt semimastic, prepared with mineral-colloid emulsifying agents and containing fibers other than asbestos, complying with ASTM D 1227, Type III or IV.

2. Spray Grade: Emulsified asphalt, prepared with mineral-colloid emulsifying agents without fibrous reinforcement, complying with ASTM D 1227, Type III.

2.3 CEMENTITIOUS SLURRY CAPILLARY (CRYSTALLINE) WATERPROOFING

A. Materials for Cementitious Slurry Capillary (Crystalline) Waterproofing: Blend of rapid hardening Portland cement, specially treated quartz sand, and activating chemicals having the following properties:

1. Color: Cement gray

2. Aggregate: Powder

3. Compressive Strength (ASTM C109) >3,000 psi at 28 days


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4. Flexural Strength (ASTM C348) >700 psi at 28 days

5. Adhesion/Bond (ASTM C321) >220 psi at 28 days

6. Shrinkage (ASTM C596) -0.02% at 28 days

7. Permeability (CRD-C 48-92) No measurable leakage through waterproofed concrete, when tested at 460 feet water head (200 psi), positive or negative water pressure

8. Water (NSF/ANSI 61): Clean, clear, non-alkaline and free of salts and other harmful elements; potable.

2.4 MISCELLANEOUS MATERIALS

A. Asphalt-Based Dampproofing

1. Primer: Asphalt primer complying with ASTM D41, for asphalt-based dampproofing.

2. Glass Fabric: Woven glass fabric, treated with asphalt, complying with ASTM D1668, Type I.

B. Cementitious Slurry Capillary (Crystalline) Waterproofing

1. Fast Setting Patching Compound: Ready-mixed cementitious waterproofing and repair mortar recommended by waterproofing manufacturer for honeycombs, tie holes, seal strips (fillets/coves, reglets), etc.

a. Compressive Strength (ASTM C109) 4,000 psi at 28 days

b. Flexural Strength (ASTM C348) 800 psi at 28 days

c. Shrinkage (ASTM C596) 0.04% at 28 days

2. Slow Setting Structural Patching Compound: Pre-blended, cementitious waterproofing and repair mortar recommended by waterproofing manufacturer larger repair areas.

a. Compressive Strength (ASTM C109) 6,000 psi at 28 days

b. Flexural Strength (ASTM C348) 1,160 psi at 28 days

c. Adhesion/Bond (ASTM C321) >225 psi at 28 days

d. Shrinkage (ASTM C596) 0.023% at 28 days

3. Plugging Compound for Active Water Leaks: Crystalline technology enhanced accelerating agent for capillary (crystalline) waterproofing products or pulverized rapid-setting rubbing cement.

a. Compressive Strength (ASTM C109) 2,800 psi at 24 hours

b. Flexural Strength (ASTM C348) 320 psi at 24 hours


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PART 3 - EXECUTION

3.1 EXAMINATION

A. Verify substrate surfaces are durable, free of matter detrimental to adhesion or application of dampproofing system.

B. Verify items which penetrate surfaces to receive dampproofing are securely installed.

3.2 PREPARATION

A. Protect adjacent surfaces not designated to receive dampproofing. Do not allow liquid and mastic compounds to enter and clog drains and conductors. Prevent spillage and migration onto other surfaces of work by masking or otherwise protecting adjoining work.

B. Clean substrate of projections and substances detrimental to work; comply with recommendation of prime materials manufacturer.

C. Do not apply dampproofing to surfaces unacceptable to manufacturer or applicator.

D. Install cant strips and similar accessories as shown and as recommended by prime materials manufacturer, even though not shown.

E. Fill voids, seal joints, and apply bond breakers, if any, as recommended by prime materials manufacturer, with particular attention at construction joints.

F. Install separate flashings and corner protection stripping, as recommended by prime materials manufacturer, where indicated to precede application of dampproofing. Comply with details shown and with manufacturer's recommendations. Pay particular attention to requirements at building expansion joints, if any.

G. Prime substrate as recommended by prime materials manufacturer.

3.3 APPLICATION, GENERAL

A. Comply with manufacturer's recommendations except where more stringent requirements are indicated and where Project conditions require extra precautions to ensure satisfactory performance of the work.

B. Hot-Applied Asphalt Dampproofing: Apply on exterior surfaces only.

C. Cold-Applied Asphalt Dampproofing:

1. For exterior surfaces, provide either emulsified or cut-back asphalt dampproofing materials, at Contractor's option.

2. For interior surfaces, provide only emulsified asphalt materials.

D. Reinforcement: At changes in plane or where otherwise shown as "reinforced", install lapped course of glass fabric in first coat of dampproofing compound before it thickens.

E. Bituminous Cant Strips: Install 2- by 2-inch cant strip of bituminous grout at base of vertical dampproofing where it meets horizontal surface.

F. Apply vertical dampproofing down walls from finished-grade line to top of footing, extend over top of footing, and down a minimum of 6 inches over outside face of footing. Extend 12 inches onto intersecting walls and footings, but do not extend onto surfaces exposed to view when the Project is completed.


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3.4 HOT-APPLIED ASPHALT DAMPPROOFING

A. Do not apply hot asphalt when substrate condition causes foaming.

B. Apply a coat of hot asphalt by mopping or spraying at a rate of 20 lb. or 2.5 gallons/100 square feet to produce a uniform film thickness of not less than 30 mils.

C. Apply a second coat, as specified, after allowing 24 hours for first coat to cure. Apply double thickness of second coat where first application has failed to produce a smooth, shiny, impervious coat.

3.5 COLD-APPLIED, CUT-BACK ASPHALT DAMPPROOFING

A. Spray Grade:

1. Brush or spray apply a coat of dampproofing at a rate of 1.25 to 2 gallons/100 square feet, depending upon substrate texture, to produce a uniform, dry-film thickness of not less than 12 mils.

2. Apply a second coat, as specified above, after allowing 24 hours for first coat to dry. Apply second coat at a rate of 0.8 to 1.25 gallons/100 square feet. Apply double thickness of second coat where first application has failed to produce a smooth, shiny, impervious coat.

B. Semimastic Grade: Brush or spray apply a coat of dampproofing at a rate of 5 gallons/100 square feet to produce a uniform, dry-film thickness of not less than 30 mils.

C. Trowel Grade: Trowel apply a coat of mastic asphalt dampproofing onto substrate at a minimum rate of 7 gallons/100 square feet, to produce an average dry-film thickness of 70 mils but not less than 30 mils at any point.

3.6 COLD-APPLIED, ASPHALT EMULSION DAMPPROOFING

A. Spray Grade:

1. Brush or spray apply a coat of asphalt emulsion dampproofing at a rate of 1.5 to 2.5 gal./100 sq ft, depending upon substrate texture, to produce a uniform, dry-film thickness of not less than 15 mils.

2. Apply in 2 coats, if necessary, to obtain required thickness, allowing time for complete drying between coats.

B. Semimastic Grade: Brush or spray apply a coat of asphalt emulsion dampproofing at a rate of 5 gal./100 sq.ft., to produce a uniform, dry-film thickness of not less than 30 mils.

C. Trowel Grade: Trowel apply a coat of mastic asphalt emulsion dampproofing onto substrate at a minimum rate of 7 gal./100 sq. ft, to produce an average dry-film thickness of 60 mils but not less than 30 mils at any point.

3.7 CEMENTITIOUS SLURRY CAPILLARY WATERPROOFING

A. A technical representative of manufacturer shall be present on site during installation.

B. Environmental Conditions:

1. Temperature: Minimum 40˚F at the surface and the surrounding air for a minimum of 24 hours prior to initiating installation and 24 hours following the completion of the installation.


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2. Moisture: Installation must be delayed in the event that the surface is wet or rain or snow is falling.

3. Surface: Apply to the surface only when it is free from dust, dirt, loose particles, cracks, grease, oil and other foreign matter that might affect the bond of the material to the concrete. Cleaning solutions shall be thoroughly removed before the start of the work. All unsatisfactory surfaces shall be etched and rinsed.

C. Mixing and application shall be in strict accordance with the written instructions of the manufacturer. This is to include surface preparation and patching.

D. Application Thickness:

1. Base Coat, one (1) coat using stiff bristle brush [1.5 lbs./sq.yd.].

2. Final Coat, one (1) coat using trowel [1.5 lbs./sq.yd.].

3. All vertical and horizontal intersections and construction joints, one (1) coat [2 lbs./sq.yd.].

3.8 PROTECTION AND CLEANING

A. Protect exterior, below-grade dampproofing membrane from damage until backfill is completed. Remove overspray and spilled materials from surfaces not intended to receive dampproofing.

B. Premises shall be kept free from the accumulation of waste materials and rubbish at all times.

C. At the completion of installation, all tools, scaffolding, and surplus materials shall be removed from the area.

D. Protect cementitious slurry capillary waterproofing from sunlight, precipitation, and frost during the curing period of 14 days.

E. If required, moisture shall be supplied during the curing period.

F. Remove all waterproofing, dampproofing and caulking materials from all surfaces where materials are not required, so as to produce a clean, neat and workmanlike job.

3.9 SCHEDULE

A. Apply Asphalt Dampproofing to the following surfaces:

1. Exterior surfaces of below grade concrete walls.

2. Where indicated on the Drawings.

B. Apply Cementitious Slurry Capillary Waterproofing to the following surfaces:

1. Exterior, exposed-to-view surfaces of concrete walls.

2. Where indicated on the Drawings.

END OF SECTION


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BLANK PAGE


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PROTECTIVE COATING SYSTEMS 09928-1

SECTION 09928

PROTECTIVE COATING SYSTEMS


1.1 WORK INCLUDED

A. All labor, materials, equipment, transportation, supervision, tools, and services necessary for the surface preparation and field painting of exposed steel surfaces; including structural steel, equipment, piping, conduits, and all appurtenances and miscellaneous items

B. All mechanical equipment shipped without a finish coat shall be field painted prior to installation.

1.2 RELATED WORK

A. Work under this Section is also subject to the requirements specified in Divisions 0 and 1 of these Contract Documents:

B. Section 01330: Submittal Procedures.

C. Section 05120: Structural Steel

D. Section 05500: Metal Fabrications

E. Section 05510: Miscellaneous Metals

F. Section 05550: Bolts, Anchor Bolts, Expansion Anchors, and Concrete Inserts

1.3 REFERENCES

A. American National Standards Institute / American Society for Testing and Materials, ANSI / ASTM

1. ANSI / ASTM D16: Definitions of Terms Relating to Paint, Varnish, Lacquer, and Related Products.

B. Ferrous Metal Standard: SSPC – Society of Protective Coatings

C. Cast and Ductile Iron Standard: NAPF 500.

D. Recommended Standards For Water Works by Great Lakes Upper Mississippi River Board of State Public Health And Environment Managers.

E. Recommended Standards For Wastewater Facilities by Great Lakes Upper Mississippi River Board of State Public Health And Environment Managers.

F. International Concrete Repair Institute (ICRI)

1.4 DEFINITIONS

A. Conform to ANSI / ASTM D16 for interpretation of terms used in this Section.


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A. Product Manufacturer: Company specializing in manufacturing quality paint and finish products intended for use in water/wastewater treatment plants with three (3) years of experience.

B. Applicator: Company specializing in water/wastewater treatment plant painting and finishing with three (3) years of experience.


A. Conform to applicable code for flame/fuel/smoke rating requirements for finishes.

B. All coatings in the following categories shall meet the USEPA Federal Clean Air Act ruling, which becomes effective on September 11, 1999. All coatings specified in the technical specification sections shall be revised accordingly to meet these requirements. The main categories targeted for Volatile Organic Compound levels are as outlined below:

1. Form Release Agents (450 g/L)

2. Primers / Undercoatings (350 g/L)

3. Bituminous Coatings / Mastics (500 g/L)

1.7 SUBMITTALS

A. Submit in accordance with Section 01330

B. Product Data

1. Provide product data on finishing products.

2. Submit manufacturer’s application instructions.

3. Submit samples in 1” x 2” size illustrating range of colors and textures available for each surface finishing product scheduled for selection.

C. Shop drawings shall include a listing of all items which the Contractor intends to paint, the paint materials designated for use on those specific items, color charts, and blank spaces to allow the Owner to insert their color selections for each item.

D. The color selections may be adjusted by the Owner and Engineer after a specific manufacturer of paint has been chosen by the Contractor, and the shop drawings have been reviewed by the Engineer. The Owner reserves the right to specify colors other than those stated in this Section, or as shown on the Drawings. It shall be the Contractor’s responsibility to have the final color selections authorized by the Owner prior to ordering any paint materials.


A. Deliver, store and protect products in accordance with Section 01600 – Materials and Equipment.

B. Deliver products to site in sealed original labeled containers; inspect to verify acceptance.

C. Container labeling to include manufacturer’s name, type of paint, brand name, color designation, and instructions for mixing and / or reducing.


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D. Store paint materials at a minimum ambient temperature of 45o F and a maximum of 90o F, in a well ventilated area, unless manufacturer’s instructions have different requirements.

E. Take precautionary measures to prevent fire hazards and spontaneous combustion.


A. All paint shall be applied in accordance with the applicable manufacturer's printed data sheet and container label outlining recommended minimum and maximum surface and air temperatures required for application. Paint shall not be applied to wet or damp surfaces and shall not be applied in rain, snow, fog or mist, or when the relative humidity exceeds 85%.

B. No paint shall be applied when it is expected that the relative humidity will exceed 85% and/or the air temperature will drop below recommended levels within 12 hours after paint application. Dew or moisture condensation should be anticipated, and if such conditions are prevalent, painting shall be delayed until certain that the surfaces are dry. Painting should be completed well in advance of the probable time of day when condensation will occur in order to permit the film an appropriate drying time prior to the formation of moisture on the surface.

C. Provide minimum lighting level of 15 foot-candles on surfaces to be finished.

1.10 EXTRA STOCK

A. Provide 1-gallon container, or small kit, of each type of paint color to owner.

B. Label each container with color, and room location, in addition to the manufacturer’s label.

C. Containers shall be tightly sealed.

1.11 ITEMS TO BE PAINTED

A. General List: These lists are intended to provide an overview of work and there may be minor or specific exceptions noted on the Drawings or Specified in Appendix A – Itemized Painting Schedule.

1. All unit process equipment and their accessories. Equipment directly connected to color coded pipe shall be painted the same color as the pipe, or as specified in Appendix A – Itemized Painting Schedule.

2. All exposed piping and appurtenances; including steel, ductile iron pipe, cast iron pipe, plastic, etc.

3. All exposed electrical conduits, brackets, etc. Properly prime galvanized surfaces as specified. Outdoor electrical apparatus and enclosures shall be coated in the same color as adjacent surfaces.

4. New building construction, including interior and exterior concrete masonry walls, all metal doors and frames, all drywall, and exposed wood.

5. All metal equipment and appurtenances not otherwise covered in the previous sections (except aluminum, chrome-plated and stainless items) shall be painted. Submerged items shall be painted black, unless otherwise indicated.


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6. All aluminum, stainless steel, and other metal surfaces in contact with dissimilar metals shall be painted at the points of contact according to Appendix B to prevent contact between dissimilar metals. Aluminum in contact with concrete shall be coated per Appendix B to prevent direct metal contact to concrete.

7. All structural steel.

B. Excluded Items: Unless otherwise shown on the Drawings, or specified in other sections, the following is a general list of those surfaces not to be painted on-site or by the manufacturer.

1. Fiberglass Items.

2. Aluminum items, unless otherwise specified.

3. Stainless steel, unless otherwise specified.

4. Chrome Plating.

5. Pre-painted items.

6. Galvanized surfaces, excluding electrical conduits, unless otherwise specified.

C. Itemized Painting Schedule: In addition to the General List of items to be painted above, Appendix A - Itemized Painting Schedule at the end of this Section lists specific items to be painted as part of the Work. This schedule is not intended to be all inclusive, but is proved to indicate major equipment or other items of importance that are to be painted. The schedule does not relieve the Contractor’s responsibility to provide a comprehensive list of items to be painted as part of the shop drawing submittal(s).



A. Paint: Interior and Exterior

1. Tnemec Company

2. AkzoNobel (International Paint, LLC Devoe Coatings)

3. Approved Alternative

2.2 MATERIALS

A. Coatings: Ready mixed, except field-catalyzed coatings.

1. Process pigments to soft paste consistency, capable of being readily and uniformly dispersed to homogeneous coatings.

2. Good flow and brushing properties; capable of drying or curing free of streaks or sags.

B. Accessory Materials: Linseed oil, shellac, turpentine, paint thinners and other materials not specifically indicated but required to achieve finishes specified or commercial quality.

C. Provide best grade of various types of coatings scheduled as regularly manufactured by acceptable paint manufacturer. Products not displaying manufacturer’s identification as “standard, best grade product,” are not acceptable.


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2.3 FINISH SCHEDULE

A. This schedule is not intended to include mention of every item requiring field painting, but is intended as a guide to finishing various surfaces throughout the project.

1. The Finish Schedule in Appendix B at the end of this Section is based, in general, on the products of Tnemec Company and AkzoNobel, and is the basis for standard of quality. The standard "or equal" clause shall apply.

2. Product substitutions shall be subject to the requirements of Section 01600. Each such request shall include the name of the specified material for which a substitute is being requested; the name of the proposed substitute material; and a complete description of the proposed substitute including performance and test data and any other information necessary for an evaluation.

3. The burden of proof of the merit of the proposed substitute is upon the Contractor. The decision of the Engineer/Owner regarding approval or disapproval of the proposed substitution shall be final.

4. Where products are proposed other than those specified by name and number in the Finish Schedule, provide submittal as required including product data sheets and performance criteria along with a new painting schedule in the same format included in this Section.

B. Undercoats:

1. Provide undercoat / primer paint produced by the same manufacturer as the finish coat.

2. Insofar as practicable, use undercoat / primer and finish coat material as part of a unified system of paint finish.

C. Provide all paint and materials supplied by one manufacturer.


3.1 INSPECTION

A. Verify that surfaces base conditions are ready to receive work as instructed by the product manufacturer.

B. Examine surfaces scheduled to be finished prior to the commencement of work.

1. Report all conditions that may adversely affect quality of the finished work prior to commencement of work.

2. Do not commence until such defects have been corrected.

C. Correct defects and deficiencies in surfaces, which may adversely affect work on this Section.

D. Beginning of installation means acceptance of existing surfaces and / or base.

3.2 PREPARATION OF SURFACES

A. Correct minor defects and clean surfaces which impact the work of this section.


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B. Impervious Surfaces:

1. Remove mildew by power washing / scrubbing with a solution of trisodium phosphate (TSP) or bleach.

2. Rinse with clean water and allow surfaces to dry.

C. Preparation of Metal Surfaces

1. SSPC-SP1 SOLVENT CLEANING: The removal of dirt, oil, grease and foreign matter with solvents or commercial cleaners using various methods of cleaning such as wiping, dipping, steam cleaning or vapor degreasing. The removal of oil and grease by solvent cleaning is included in all other SSPC Surface Preparation Specifications.

2. SSPC-SP2 HAND TOOL CLEANING: The removal of loose rust and mill scale, or old paint by hand wire brushing, hand scraping, hand chipping or hand sanding.

3. SSPC-SP3 POWER TOOL CLEANING: The removal of loose rust and mill scale by mechanical means such as power sanders, wire brushes, chipping hammers, abrasive grinding wheels or needle guns.

4. SSPC-SP4 FLAME CLEANING: The dehydration of the surface by rapidly heating with a high temperature, high-velocity oxyacetylene flame followed by wire brushing and hand scraping to remove loose rust and mill scale.

5. SSPC-SP5 WHITE METAL BLAST CLEANING: The complete removal of all visible rust, mill scale, paint and foreign matter by compressed air nozzle blasting, centrifugal wheels or other specified method, leaving an overall, uniformly gray-white metallic appearance.

6. SSPC-SP6 COMMERCIAL BLAST CLEANING: The removal of at least sixty-six percent of all visible rust, mill scale, paint and other foreign matter from each square inch of surface by compressed air nozzle blasting, centrifugal wheels or other specified methods.

7. SSPC-SP7 BRUSH-OFF BLAST CLEANING: The removal of loose rust, mill scale, paint and foreign matter from the surface by compressed air nozzle blasting, centrifugal wheels or other specified methods.

8. SSPC-SP8 PICKLING: The complete removal of all rust, mill scale and foreign matter by chemical reaction or electrolysis in acid solutions. The degree of cleanliness is similar to SSPC-SP5 White Metal Blast Cleaning.

9. SSPC-SP9 WEATHERING AND CLEANING: This is a method of preparing unpainted metal surfaces for coating by weathering metals to remove all or part of mill scale followed by blast cleaning.

10. SSPC-SPC10 NEAR-WHITE METAL BLAST CLEANING: The removal of ninety-five percent of all visible rust, mill scale, paint and other foreign materials from each square inch of surface by compressed air nozzle blasting, centrifugal wheels or other specified reason.

11. On galvanized surfaces, prepare in accordance with the methods outlined in ASTM D 6386-99 Standard Practice for Preparation of Zinc (Hot Dipped Galvanized) Coated Iron and Steel Product and Hardware Surfaces for Painting.


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12. On stainless steel surfaces, prepare by solvent cleaning prior to using any one of the methods in SSPC-SP1. Only solvents or cleaning solutions containing less than two hundred (200) ppm of halogens shall be used to prevent stress corrosion cracking. Abrasive blast cleaning procedures outlined by Steel Structures Painting Council for carbon steel may also be used for stainless steel. Only very hard silica sand or other abrasive material should be used for a fast cutting action and to obtain a sharp angular profile.

D. Shop Primed Steel Surfaces

1. The paint systems shown in appendix B are to be used for equipment and piping delivered to the site even though they may already be shop primed. A shop prime coat shall not be substituted for the surface preparation of prime coats required on-site by the paint systems listed in that Section.

2. Sand or scrape to remove loose primer and rust.

3. Feather edges to form a smooth transition to tight existing paint.

4. Shop Prime Coat: Apply per Finish Schedule in Appendix B at the end of this Section in accordance to the requirements for prime coating.

E. Concrete and Masonry Surfaces

1. All concrete and masonry surfaces to be painted or sealed shall be clean, dry and free of dirt, oils, dust, grease, wax, flaking or loose paint, efflorescence and other deleterious materials. All cracks, chips and other defects in plain concrete and masonry surfaces shall be filled prior to coating or sealing.

2. New concrete or masonry should not be coated for at least twenty-eight (28) days to permit the concrete or mortar to cure and dry out.

3. Prepare concrete or masonry surfaces to be coated in accordance with SSPC SP-13. Surface profile shall be accordance with ICRI CSP standards as recommended by the manufacture based on coating system and the intended environment. The surface of concrete or masonry to be coated should be examined for defects such as fins, protrusions, bulges and mortar spatter. These defects should be corrected by grinding or scraping. Remove non-degraded release agents, oil, wax, and grease by scraping off heavy deposits and solvent cleaning with a hot trisodium phosphate solution. Allow time to dry thoroughly before coating.

F. Cast and Ductile Iron Piping

1. Preparation per NAPF 500 requirements, latest edition.

G. Wood surfaces

1. Wood shall be clean and dry. Remove surface deposits of sap or pitch by scraping and wiping clean with mineral spirits or VM&P naphtha. Seal knots and pitch pockets with shellac reduced with equal parts of shellac thinner (denatured alcohol) before priming. Sand rough areas with the grain, starting with medium grit sandpaper and finishing with fine grit. Remove sanding dust. After prime coast is dry, fill cracks and holes with putty or spackling compound. When filler is hard, sand flush with the surface using fine grit sandpaper. Sand lightly between coats with fine grit, open-coated sandpaper.


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H. PVC Pipe

1. All surfaces to be uniformly and thoroughly scarified using a medium grit sandpaper. Any dust or other contaminates remaining after sanding shall be removed with dry, oil free compressed air or by vacuum after cleaning.

I. Gypsum Drywall Construction

1. Sand joint compound with fine-grit, open-coated sandpaper to provide a smooth flat surface. Avoid heavy sanding of the adjacent wallboard surfaces, which will raise the nap of the paper covering. Remove dust from the surface by wiping with clean rags or other means. If additional joint finishing is required to provide a smooth surface, the same joint compound or ready-mixed spackling compound shall be used. Putty, patching pencils, caulking, or masking tape shall not be applied to the drywall surfaces to be painted. Lightly scuff-sand tape joints after priming to remove raised paper nap. Take care not to sand through the prime coat and remove dust by wiping with clean rags.

3.3 PROTECTION

A. Protect elements surrounding work of this Section from damage or disfiguration.

B. Repair damage to other surfaces caused by work of this section.

C. Furnish drop cloths, shields, and protective methods to prevent spray or droppings from disfiguring other surfaces.

D. Remove empty paint containers from site.

3.4 APPLICATION

A. Apply products in accordance with manufacturer’s instructions.

B. All painting shall be done in the best manner by skilled workmen and in accordance with the SSPC Good Painting Practices PA1 and the manufacturer’s application recommendations. The Contractor shall follow OSH requirements. Extreme care shall be taken around volatile materials, which could pose a fire or explosion hazard. Precautions shall be taken to avoid workmen from inhaling toxic or dangerous vapors or paint particles. Containers for use shall be opened in the presence of the Engineer immediately before use.

C. Paint shall be thoroughly stirred, strained, and kept at a uniform consistency during application. Where necessary, packaged paint other than cement-emulsion filler may be thinned immediately prior to application in accordance with the manufacturer’s directions if authorized by the Engineer, but not in excess of one pint of thinner per gallon of paint.

D. Surfaces that have been cleaned or pretreated shall be given a first coat of paint as soon as practical after surface preparation, prior to any deterioration of the prepared surfaces.

E. Each coat shall be applied at the rate and to the film thickness specified in Appendix B. One (1) gallon of paint as originally furnished must not cover a greater area than when applied by spray gun than when applied by brush unthinned.


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F. All paint shall be thoroughly and smoothly applied or brushed out to a uniform film without runs or sags. Each coat of finish shall be allowed to completely cure and dry hard before application of the succeeding coat. First coats for specific metal surfaces shall be applied by brush, if required by the Engineer. When the trim has been shop primed, any subsequent coats may be applied by brush, roller, or spray. Other surfaces may be coated by brush, roller, or spray, except for filler coats. Sand lightly between coats if required to achieved specific finish.

G. Apply each coat of paint in contrasting color than the preceding coat unless otherwise approved by the Engineer.

H. Metal surfaces adjacent to other surfaces receiving water-based paints shall be primed and/or touched-up prior to the application of the water-based paints. The first coat on plaster shall include touching-up or application of primer-sealer as necessary to produce a uniform color and gloss. Application of styrene-butadiene filler shall be in accordance with the manufacturer’s instructions. Surface voids, pores, and cracks shall be filled, and the completed dry film shall be free from pinholes or other imperfections. Surface irregularities need not be completely filled. The coasting material shall not be applied over caulking compound.

I. Paint on metal, masonry, plaster, or concrete areas of considerable size (except floors) may be sprayed by skilled workmen only. Respirators shall be worn by those in proximity of spray painting. The nozzle shall be held perpendicular to the surface being painted and the coat applied uniformity, thoroughly wetted, and properly bonded to the surface. Immediately after spraying, remove all surplus paint and smooth out all runs and sags by brushing out. Adjacent surfaces shall be protected from drips, spatter, and over spray.

3.5 PAINTING EQUIPMENT

A. Brushes shall be new and be the size and type best suited for the particular work. Brushes shall be kept clean and stored properly when not in use. If rollers are used for applying enamel, they shall have a short nap, as required by the manufacturer.

B. Spraying equipment shall be subject to the Engineer’s authorization. Compressors shall be motor-driven, oil and water free, and shall be set in locations designated by the Engineer and connected and used without interfering with the work of other trades. The paint spray container shall have an efficient agitator for materials requiring this. All flexible hose, nozzles, and equipment shall be thoroughly cleaned after each day’s work and maintained in first-class working conditions.

3.6 FINISHING MECHANICAL EQUIPMENT AND PIPING

A. Finish paint shop primed equipment to color selected.

B. Prime and paint insulted and exposed pipes, hangers, brackets, collars, and supports except where items are prefinished.

C. Replace identification markings on mechanical equipment when painted accidentally.


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D. Pipe Color Code

1. All new, exposed, interior, and submerged piping shall be painted. Plastic pipe shall be painted only in order to indicate its use according to the Pipe Color Code, and only that portion which is exposed and not submerged shall be painted. Plastic pipe which is used for purposes other than those mentioned in the Pipe Color Code shall not be painted. In general, the only application for asphalt dipped pipe shall be buried installations. Pipe colors shall be according to the following schedule. The direction of flow of the contents of the pipe shall be stenciled on the piping. Permanently attached plastic markers may be used in lieu of the stenciling. Shop drawings shall indicate stencil or plastic marker method.

2. Water: Color banding and identification of piping (flow arrows, naming, numbering) in accordance with following schedule:

a. Raw water line Olive b. Settled or Clarified water Aqua c. Potable Water Blue d. Alum or Primary Coagulant Orange e. Ammonia White f. Carbon Slurry Black g. Caustic Yellow w/ green band h. Chlorine Yellow i. Fluoride Light blue w/ red band j. Lime Slurry Light Green k. Ozone Yellow w/ orange band l. Phosphates Light green w / red band m. Potassium Permanganate Violet n. Soda Ash Light green w/ orange band o. Sulfuric Acid Yellow w/ red band p. Sulfur Dioxide Light green w/ yellow band q. Backwash Waste Light brown r. Sludge Dark brown s. Sewage (wastewater) line Gray t. Compressed Air line Green u. Gas Red v. Polymers or Coagulant Aids Orange w/ green band

The contents and direction of flow shall be stenciled on the piping in a contrasting color.

3. Wastewater: Color banding and identification of piping (flow arrows, naming, numbering) in accordance with following schedule:

a. Raw Sludge line Brown w/black bands b. Sludge Recirc. Suction line Brown w/yellow bands c. Sludge Draw off line Brown w/orange bands d. Sludge Recirc. Discharge line Brown e. Non-potable water line Blue w/black bands f. Potable Water line Blue g. Sewage (wastewater) line Gray h. Chlorine Line Yellow i. Sulfur Dioxide Yellow w/red bands j. Compressed Air line Green k. Water lines for heating digesters Blue w/6” band @ 30” spacing


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l. Plumbing drains and vents Black

The contents and direction of flow shall be stenciled on the piping in a contrasting color.

4. Pipe Lettering Size

Pipe O.D. (inches) Letter Height (inches) 3/4 to 1-3/4 1/2 1-1/2 to 2 3/4 2-1/2 to 6 1-1/4 8 to 10 2-1/2 Over 10 3-1/2 3.7 CLEANING

A. As work proceeds, promptly remove paint where spilled, splashed or spattered.

B. During progress of work, maintain premises free of unnecessary accumulation of tools, equipment, surplus materials and debris.

C. Collect cotton waste, cloths, and materials that constitute a fire hazard; place in closed metal containers and remove daily from site.

D. Upon completion of work, leave premises neat and clean, to the satisfaction of Engineer.


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APPENDIX A - ITEMIZED PAINTED SCHEDULE

A. New Items to be Painted Color

1. All new exposed pump station piping.

2. All new exposed piping in vaults.

3. All new exposed chemical solution piping.

4. All new steel piping supports.

5. New steel bollards.

6. New pumps.

1. Sherwin Williams – Steel Master 9500 Turbine Blue (see Note 1)


3. Per paragraph 3.6.D.2.

4. Match piping color.

5. Safety yellow.


B. Existing Items to Be Painted Color

N/A N/A

Notes:

1. The City of Conroe has standardized on the following Sherwin Williams paint coating system for all pumping equipment and exposed pump suction and discharge piping:

a. Prime Coat: Ken Kromik Off White Primer B50 WZ 1 6401-15325

b. Finish Coat: Steel Master 9500 Silicone Alkyd, High Gloss IFC 411X

Color: Custom Manual Match – “Turbine Blue”

844 Colorant OZ 32 64 128 Pg-Phth Green 8 6 1 - Pb-Blue 10 30 - - QV-Quin Violet 6 38 - - TW-White 32 16 - -

Dry Film Thickness: 10 to 12 mils

END OF APPENDIX A


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APPENDIX B – FINISH SCHEDULE

Surface Surface

Preparation Primer

Inter-mediate

Finish

Steel-Structural Tanks, Pipes, Equipment Exterior, Non-Immersion

SSPC-SP6 TP2 or IPP1

TI2 or IPI1

TF1 or IPF1

Steel-Structural Tanks, Pipes, Equipment Interior, Non-Immersed


TI2 or IPI1

TF4 or IPF2

Steel-Structural Tanks, Pipes, Equipment Interior, Non-Immersed (2nd Option)

SSPC-SP6 IPP2 N/A IPF2

Steel-Structural Tanks, Pipes, Equipment Immersion, Potable Water


TI5 or N/A (IP)

TF8 or IPF3

Steel-Structural Tanks, Pipes, Equipment Immersion, Non-Potable Water


TI2 or N/A (IP)

TF4 or IPF2

Steel-Structural Tanks, Pipes, Equipment Below Grade


N/A TF5 or IPF4

Factory Primed Steel Exterior Exposed

N/A N/A TI4 or IPI3

TF1 or IPF1

Factory Primed Steel Interior Exposed

N/A N/A TI4 or IPI3

TF2 or IPF2

PVC Pipe Exterior Exposed

Scarify TP1 or IPP1

N/A TF1 or IPF1

PVC Pipe Interior Exposed

Scarify TP1 or IPP1

N/A TF1 or IPF2


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Surface Surface

Preparation Primer

Inter-mediate

Finish

Ductile Iron Pipe Exterior Exposed Non-Immersed

NAPF 500-03-03

TP2 or IPP1

TI2 or IPI3

TF1 or IPF1

Ductile Iron Pipe Interior Exposed Non-Immersed

NAPF 500-03-03

TP2 or IPP1

TI2 or N/A (IP)

TF4 or IPF2

Ductile Iron pipe Immersion Non-Potable Water

NAPF 500-03-03

TP2 or IPP1

TI2 or IPI1

TF4 or IPF2

Ductile Iron Pipe Immersion Potable Water

NAPF 500-03-03

TP2 or IPP5

TI5 or N/A (IP)

TF8 or IPF3

Ductile Iron Pipe Below Grade

NAPF 500-03-03

TP2 or IPP4

N/A TF5 or IPF4

Galvanized Steel and Non-Ferrous Metals Exterior Exposed

ASTM D 6386-99

TP1 or IPP1

N/A TF1 or IPF1

Galvanized Steel and Non-Ferrous Metals Interior Exposed

ASTM D 6386-99

TP1 or IPP1

N/A TF2 or IPF2

Galvanized Steel and Non-Ferrous Metals Immersion, Potable Water

ASTM D 6386-99

TP2 or IPP5

N/A TF10 or

IPF3

Galvanized Steel and Non-Ferrous Metals Immersion, Non-Potable Water

ASTM D 6386-99

TP1 or IPP1

N/A TF4 or IPF2

Galvanized Steel and Non-Ferrous Metals Chain Link Fence

ASTM D 6386-99

TP1 or IPP1

N/A TF1 or IPF1

Concrete Exterior Exposed

SSPC-SP 13 TP4 or IPP6

TI3 or IPI1

TF7 or IPF5


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Surface Surface

Preparation Primer

Inter-mediate

Finish

Concrete Exterior Exposed Below Grade

SSPC-SP 13 N/A N/A TF5 or IPF6

Concrete Immersion Non-Potable Water

SSPC-SP 13 ICRI-CSP 5

TP3 or IPP7

N/A or IPI1 TF4 or IPF2

Concrete Immersion Potable Water

SSPC-SP 13 ICRI-CSP5

TP3 or IPP6

N/A or IPI2 TF10 or

IPF3

Concrete Immersion Brine Tank


TP3 or IPP8

TI5 or N/A (IP)

TF12 or IPF7

Concrete Interior Exposed

SSPC-SP 13 ICRI-CSP 1-3

TP3 or IPP2

Patch as required

N/A TF4 or IPF2

Concrete Secondary Containment Severe Conditions Interior Exposed

SSPC-SP 13 ICRI - CSP 5

TP3 or IPP6

TI6 or IPI4

TF9 or IPF8

Concrete Floors Non-Slip Clear Finish


TP6 N/A TF10

Concrete Masonry Exterior Exposed

Clean and Dry

TP4 or IPP9

TI3 or IPI1

TF7 or IPF1

Concrete Masonry Interior Exposed

Clean and Dry

TP5 or IPP9

TI2 or IPI1

TF4 or IPF2

Plaster and Wallboard Interior Exposed

Clean and Dry

TP4 or IPP10

N/A TF3 or IPF9

Wood Interior and Exterior

Clean and Dry

TP4 or IPP11

N/A TF3 or IPF10


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Surface Surface

Preparation Primer

Inter-mediate

Finish

Insulated Pipe

Interior

Clean and

Dry

TP4 or IPP6

TI7 or

IPI5

TF6 or IPF11

Concrete: Severe Wastewater (H2S) Environments


TP3 or IPP8

TI8 or

N/A (IP)

TF11 or IPF7

Steel: Severe Wastewater (H2S) Environments

SSPC-SP 5, 3.0 mil minimum profiled

N/A TF11 or N/A (IP)

TF11 or IPF7

Steel-Structural

Tanks, Pipes, Equipment

Exterior, Non-Immersion – ELEVATED WATER STORAGE TANKS – NEW CONSTRUCTION

SSPC-SP10 IPP12 IPI6 IPF1

Steel-Structural


Exterior, Non-Immersion - ELEVATED WATER STORAGE TANKS – MAINTENANCE & REPAIR (Option 1 – polyurethane)

SSPC-SP7

Min: SSPC-SP2/SP3

IPP13

Spot Prime

IPI6 IPF1

Steel-Structural


Exterior, Non-Immersion - ELEVATED WATER STORAGE TANKS – MAINTENANCE & REPAIR (Option 2 – acrylic)

Power Wash w/Devprep 88 (min 2000 psi)

IPP13

Spot Prime

IPI5 IPF11

E. Tnemec Prime (TP) Coat:

TP1 Series N69Hi-Build Epoxoline II, 2.0-3.0 mils dry

TP2 Series 1 Omnithane 2.5 – 3.5 mils

TP3 Series 218 MortarClad, min. 1/32”

TP4 Series 151 Elasto-Grip FC, 0.7 – 1.5 mils dry


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TP5 Series 130 EnviroCrete, 60 - 80 sq. ft./gal spread rate for porous CMU, 85 to 115 sq. ft./gal. for dense CMU

TP6 Series 201 Epoxoprime

F. Tnemec Intermediate (TI) Coats:

TI1 Series N69 Hi-Build Epoxoline II, 2.0-3.0 mils dry

TI2 Series N69 Hi-Build Epoxoline II, 4.0-6.0 mils dry

TI3 Series 156 EnviroCrete, 4.0-8.0 mils dry

TI4 Series 27 Typoxy, 2.0-3.0 mils dry

TI5 Series 140 Pota-Pox, 4.0-6.0 mils dry

TI6 Series 237SC PowerTread 8.0-10.0 mils dry

TI7 Series 6 Tneme-Cryl, 2.0 – 3.0mils dry

TI8 Series 434 Perma-Shield H2S, 1/8” min. thickness

G. Tnemec Finish (TF) Coats:

TF1 Series 73 Endura-Shield, 2.0-3.0 mils dry

TF2 Series N69 Hi-Build Epoxoline, 2.0-3.0 mils dry

TF3 Series 113 HB Tneme-Tufcoat, 4.0 – 6.0

TF4 Series N69Hi-Build Epoxoline II, 4.0-6.0 mils dry

TF5 Series 46H-413 Hi-Build Tneme Tar, 14.0-20.0 mils dry

TF6 Series 6 Tneme-Cryl, 2.0-3.0 mils dry

TF7 Series 156 EnviroCrete, 4.0-8.0 mils dry

TF8 Series N140 Pota-Pox Plus, 4.0 to 6.0 mils dry

TF9 Series 282 Tneme-Glaze, 6.0 – 8.0

TF10 Series 294 Clear CRU 2.0–3.0 mils dry

TF11 Series 435 Perma-Glaze 15.0 – 2.0 mils

H. International Paint (IPP) Prime Coats:

IPP1 Devoe Devran 201H, 2.0-3.0 mils dry

IPP2 Devoe Devran 224HS, 4.0-6.0 mils dry or

International Intergard 345, 4.0-6.0 mils dry

IPP3 Devoe Bar Rust 233H, 4.0-6.0 mils dry or

International Interseal 670HS, 4.0-6.0 mils dry


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IPP4 Devoe DevTar 5A-HS, 6.0-8.0 mils dry

IPP5 Devoe Bar Rust 233H, 2.0-3.0 mils dry (thinned) or

International Interseal 670HS, 2.0-3.0 mils dry (thinned)

IPP6 Pre-Prime 167, 1.0-1.5 mils dry

IPP7 Devoe Devfil 145

IPP8 Enviroline 50 Moisture Tolerant Primer, 2.0-4.0 mils dry or

Ceilcote 680M Primer, 2.0-4.0 mils dry

IPP9 Devoe Bloxfil 4000

IPP10 Devoe Tru-Glaze 4030, 2.0-3.0 mils dry

IPP11 Devoe Devflex 4020

IPP12 Devoe Cathacoat 302H, 2.5-4.0 mils dry or

International Interzinc 22, 2.5-4.0 mils dry

IPP13 Devoe Bar Rust 231, Spot Prime or

International Intergard 345, Spot Prime

I. International Paint Intermediate (IPI) Coats:

IPI1 Devoe Devran 224HS, 4.0-6.0 mils dry or


IPI2 Devoe Bar Rust 233H, 4.0-6.0 mils dry or


IPI3 Devoe Devran 201H, 2.0-3.0 mils dry

IPI4 Devoe Devchem 253, 5.0-6.0 mils dry

IPI5 Devoe Devflex 659, 2.0-3.0 mils dry

IPI6 Devoe Bar Rust 231, 4.0-6.0 mils dry or


J. International Paint Finish (IPF) Coats:

IPF1 Devoe Devthane 379, 2.0-3.0 mils dry or

International Interthane 990, 2.0-3.0 mils dry

IPF2 Devran 224HS, 4.0-6.0 mils dry or


IPF3 Devoe Bar Rust 233H, 4.0-6.0 mils dry or


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IPF4 Devoe DevTar 5A-HS, 6.0-8.0 mils dry

IPF5 Devoe Devthane 378, 2.0-3.0 mils dry or

International Interthane 870, 2.0-3.0 mils dry

IPF6 Interzone 954 or Devtar 247, 16.0-20.0 mils dry

IPF7 Enviroline 222, 20.0-100.0 mils dry or

Ceilcote 663SG, 60.0-120.0 mils dry

IPF8 Devoe Devchem 258, 5.0-6.0 mils dry

IPF9 Devoe Tru-Glaze 4418, 2.0-3.0 mils dry

IPF10 Devoe Devflex 4216, 2.0-3.0 mils dry

IPF11 Devoe Devflex 659, 2.0-3.0 mils dry

END OF APPENDIX B

END OF SECTION


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BLANK PAGE


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CLOSE COUPLED HORIZONTAL END SUCTION PUMP

11100-1

SECTION 11100


P A R T I – G E N E R A L


A. Requirements for providing close coupled, horizontally mounted end suction pumps, complete with motor, base, spare parts, painting, appurtenances and accessories, shop drawings, shop tests, and field tests. Contractor shall install pumps in accordance with manufacturer’s recommendations and drawings.

B. Provide pumps in accordance with the Pump Schedule included in Appendix A at the end of this Section.

1.2 WARRANTY

A. The manufacturer shall guarantee in writing that the equipment furnished is appropriate for the intended service and shall be free of manufacturing and fabrication defects in material and workmanship for a period of one (1) year commencing from the date of Final Completion and acceptance.


The work in this section is subject to the requirements of applicable portions of the following standards: A. HI – Hydraulic Institute B. ANSI – American National Standards Institute C. ASTM – American Society for Testing and Materials D. IEEE – Institute of Electrical and Electronics Engineers E. NEMA – National Electrical Manufacturers Association F. NEC – National Electrical Code G. ISO – International Standards Organization H. UL – Underwriters Laboratories, Inc. I. CSA –Canadian Standards Association J. OSHA – Occupational Safety & Health Administration K. ASME – American Society of Mechanical Engineers L. IEC– International Electrotechnical Commission M. ETL – Electrical Testing Laboratories N. NSF – National Sanitation Foundation


A. To ensure unity of responsibility, the complete pump unit, including pump, base, and motor, shall be supplied, tested, and warranted by the manufacturer. The pump, base, and electric motor shall be factory assembled at the pump manufacturer’s facility.

B. The equipment specified under this section is to be standard pumping equipment manufactured by a company with no less than fifteen (15) years’ experience in the manufacture of such equipment. Upon request by the engineer, the manufacturer shall provide proof of such experience by providing installation lists, brochures, catalog cuts, etc.


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11100-2

C. The manufacturer shall have a quality management system in place and shall be ISO 9001 certified.

P A R T 2 – P R O D U C T S

2.1 GENERAL

A. Pumps shall be a close coupled, horizontally mounted single stage, end suction design of cast iron and bronze fitted construction suitable for chlorinated potable drinking water applications.

B. Pumps shall meet the operating conditions as specified in the Pump Schedule included in Appendix A at the end of this Section.


A. The Owner wishes to standardize pumping equipment at all of their facilities.

B. All pumping equipment shall be PACO model LC as manufactured by Grundfos CBS Inc., 902 Koomey Road, Brookshire, Texas 77423. No product substitutions will be allowed.

2.3 PUMP DESCRIPTION

A. All pumps shall be of the back pull-out design so that the rotating element can be removed from the casing without disconnecting the suction or discharge piping. The casing material shall be close-grained cast iron, ASTM A48 Class 30, with a minimum tensile strength of 30,000 P.S.I. Volute shall have integrally cast suction and discharge connections, gauge ports at nozzles, and vent and drain ports. Pumps with specific speed greater than 1600 shall have double volute casing. Pumps with discharge size 3” and larger shall have suction splitter to reduce pre-rotation and improve efficiency. Casings shall be designed for scheduled working pressure and can withstand hydrostatic test at 150% of the maximum working pressure under which the pump could operate at design speed.

B. Pumps with impeller diameter larger than 5” shall be fitted with bronze renewable case wear rings.

C. Pumps with discharge size 2.5” and larger shall have full flanged connections on both suction and discharge. Suction and discharge flanges shall be drilled to ANSI B16.1 Class 125 standards and be machined flat face.

D. The motor shaft shall be of stainless steel AISI 416 with bronze sleeves covering the wetted area of the shaft.

E. The pump manufacturer shall recommend the proper mechanical seal based on the pressure, temperature and liquid outlined on the equipment schedule. Mechanical seals, at a minimum, shall have ceramic stationary seats, carbon rotating rings, Buna elastomers and stainless steel hardware. Application of a mechanical seal shall be internally flushed type, without requiring external flushing lines. Seals shall be capable of being inspected and easily replaced without removing the piping or volute.

F. Impeller shall be of the enclosed Francis vane type, single suction design, made of aluminum bronze, ASTM B148 UNS 95400, both hydraulically and dynamically balanced to ISO 1940-1:2003 balance grade G6.3 and keyed to the shaft. The impeller shall be trimmed to meet the specific hydraulic requirements.

G. Pump Construction. The standard material of construction for the pump shall be as below. Special material shall be available as option to suit the liquid pumped.


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11100-3

1. Volute: Cast Iron ASTM A48 - Class 30

2. Case Wear ring: Tin Bronze ASTM B584-90500

3. Impeller: Aluminum Bronze ASTM B148 UNS 95400

4. Shaft: Stainless Steel AISI 416

5. Shaft Sleeve: Bronze III932 C89835

6. Mechanical Seals: Carbon – Ceramic with Buna Elastomers and Stainless Steel hardware

H. Pump rotation shall be clockwise as viewed from the motor end.

I. Entire pumping unit shall be mounted on a cast iron drip rim base using cap screws. Pumps shall not be secured with floor studs.

J. Pump shall be of a maintainable design for ease of maintenance and should use machine fit parts that are easily disassembled.

K. Pump shall be NSF-61 certified.

2.4 MOTORS

A. Pump and motors shall be factory assembled.

B. Motors shall be suitably sized per ISO5199 and shall meet NEMA specifications and conform to the standards outlined in EISA 2007.

C. Motor shall be of the horsepower and speed shown in the Pump Schedule in Appendix A. Pumps requiring larger horsepowers shall not be acceptable. Pump shall be close coupled to a 3-phase, 60 Hertz, 480 volt, horizontal, TEFC motor with 1.15 service factor. 40°C ambient.

D. Motors shall be in conformance with the requirements of Section 16222, AC Electric Motors - 100 HP and Below.

2.5 PUMP COATINGS A. The Pump Supplier shall prepare all carbon steel and cast iron surfaces by blast cleaning, per SSPC-SP10, to a near white finish to achieve a surface anchor profile of 2 to 3 mils per ASTM D4417. All surfaces shall be shop prime painted with a coating compatible with the finish coating system specified herein.

B. All interior carbon steel or cast iron surfaces of the pump casing or other surfaces in contact with the pumped liquid shall be shop painted with a NSF Standard 61 approved two part epoxy coating, such as Carboguard 891 or Tnemec N140 Pota-Pox Plus, applied in two coats of 4 to 6 mils dry film thickness (DFT) each. Final DFT shall be 10 to 12 mils. Final color shall be white.

C. All pump exterior carbon steel and cast iron surfaces, including pump support base, shall be shop finish coated in accordance with Specification Section 09928.

D. Factory applied fusion bonded epoxy (FBE) is an acceptable alternative.


WATER PLANTS


11100-4

E. Apply coatings in accordance with the coating manufacturer’s latest published technical data sheets, application sheets and MSD sheets.

F. Stainless steel or bronze surfaces shall not be painted. Coat machined, polished, and non-ferrous metal surfaces and similar unpainted surfaces with corrosion prevention compound which shall be maintained during storage and until equipment begins operation.

2.6 NAMEPLATES

A. Nameplates and other data plates shall be of stainless steel, suitably secured to the pump.

B. Include the following information as a minimum on pump name plate: manufacturer’s model and serial numbers, rated capacity, rated head, and pump speed.

P A R T 3 - EXECUTION


A. Deliver all equipment to storage locations designated by the Owner. Contractor shall provide necessary equipment to unload all equipment. Provide recommendations and instructions on the proper methods for handling, storing, and protecting all equipment delivered.

B. All equipment shall be crated to protect against any damage.

C. All parts shall be properly protected so no damage or deterioration shall occur during a prolonged delay from the time of shipment until installation is completed and the equipment is ready for operation.

D. Finished iron or steel surfaces not painted shall be properly protected to prevent rust and corrosion.

E. The finished surfaces of all exposed flanges shall be protected by wooden blank flanges, strongly built and securely bolted thereto.

F. Factory assembled parts and components shall not be dismantled for shipment unless permission is received in writing from the Engineer.

3.2 FACTORY TESTING AND CERTIFICATION

A. Each pump shall undergo a certified hydrostatic test at 150% of the pressure developed at shut-off head.

B. A certified performance test shall be performed on each unit utilizing its specified drive.

C. All tests shall be performed in accordance with the Hydraulic Institute’s Rotodynamic Pumps for Hydraulic Performance Acceptance Tests – ANSI/HI 14.6 (2011).

D. Six (6) evenly spaced test points shall be taken and shall include conditions at shut-off (zero flow) and the operating points specified herein. Preliminary test data must be submitted to the owner seven days prior to the actual test date.

E. The Engineer and/or a representative of the Owner shall be given four (4) weeks’ notice of the testing dates and shall have the opportunity to witness these tests.


WATER PLANTS


11100-5

3.3 INSTALLATION

A. Services of the manufacturer's factory representative, who is specifically knowledgeable in the type of equipment specified herein, shall be provided to assist the Contractor during installation, inspection, testing, start-up, and to provide training of Owner’s personnel.

B. Services of the manufacturer’s factory representative shall be provided for a minimum of two (2) 8-hour days onsite for installation assistance, inspection, testing, start-up and training. At least two (2) separate trips shall be made, one during the installation period and the second during the inspection, testing, start-up and training period. All costs, including travel, lodging and meals, shall be included in the Contractor’s bid. Costs for additional days onsite required due to problems associated with installation issues or problems with delivered equipment shall be borne by the Contractor at no additional compensation to the Contract.


A. Equipment assembled, installed, and painted by the Contractor shall be approved by the both the manufacturer's factory representative and the Owner’s representative.

B. Following installation approval, equipment shall be placed in operation under the supervision of manufacturer’s factory representative. Manufacturer’s factory representative shall subsequently provide written certification of proper equipment installation and operation to Owner and Engineer.

3.5 START-UP AND TRAINING

A. Upon complete installation of equipment by Contractor, including placement of equipment, setting and leveling the equipment, piping and electrical connections to all the equipment specified herein, the manufacturer’s factory representative will approve the installation and begin start up and training.

B. Upon approval of the installation, the services of the manufacturer's factory representative shall inspect all system components for proper connection and alignment and assist the Contractor in placing the equipment in a proper operating condition.

C. Startup tests shall be performed by the manufacturer’s factory representative, under the supervision of the Contractor with the Owner’s participation as required, to determine that all features and equipment systems and subsystems have been properly designed, manufactured, installed and adjusted, function properly as specified and are capable of operating simultaneously and continuously in the local and remote control modes at all capacities throughout their operating range.

END OF SECTION


WATER PLANTS


11100-6

APPENDIX A

PUMP SCHEDULE

WP 14 PUMP LIST

PUMP # PACO MODEL SUCTION/DISCHARGEMOTOR

(HP)NOMINAL FLOW

(GPM)TDH (FT)

STATUS

WP14-1-ESH 40129 LC 5" / 4" 40(1) 750 150 EXISTING

WP14-2-ESH 40129 LC 5" / 4" 40(1) 750 150 EXISTING

WP14-3-ESH 40129 LC 5" / 4" 50 750 150 PROPOSED

WP 14 PUMP DESIGN CRITERIA

RATED BEP SECONDARY SECONDARY SHUTOFFNON-

OVERLOADING

CAPACITY(GPM)

750 1,078 350 1,400 0 1,516

TDH (FT)

150 134.8 157.1 103.1 155.3 85.2

PUMP EFFICIENCY(%)

77.6 82.8 55.1 74.4 - 65.3

POWER(HP)

36.6 44.3 25.2 48.9 - 49.9

MAX SPEED(RPM)

1,780 1,780 1,780 1,780 - 1,780

NPSHr(FT)

12.05 13.5 - 21.9 - 29.3

Notes:1. Existing Motors on Pumps 1 & 2 to be replaced with 50 HP Motors.

WP 15 PUMP LIST


(HP)NOMINAL FLOW

(GPM)TDH (FT)

STATUS

WP15-1-ESH 50157 LC 6" / 5" 75 1,000 160 PROPOSED





OVERLOADING

CAPACITY(GPM)

1,000 1,431 500 1,700 0 1,886

TDH (FT)

160 144.2 168.9 127.5 170.8 111.3

PUMP EFFICIENCY(%)

79.0 83.5 57.7 81.5 - 77.3

POWER(HP)

51.2 62.4 36.9 67.1 - 68.6

MAX SPEED(RPM)

1,780 1,780 1,780 1,780 - 1,780

NPSHr(FT)

9.0 10.8 8.5 13.0 - 15.1


WATER PLANTS

VERTICALLY MOUNTED

HORIZONTAL SPLIT CASE PUMP 11300-1

SECTION 11300

VERTICALLY MOUNTED, HORIZONTAL SPLIT CASE PUMP



A. Requirements for providing vertically mounted, single stage, double suction horizontal split case pumps, complete with motor, base frame, coupling, spare parts, painting, appurtenances and accessories, shop drawings, shop tests, and field tests. Contractor shall install pumps in accordance with manufacturer’s recommendations and drawings.

B. Provide pumps in accordance with the Pump Schedule included in Appendix A at the end of this Section.

1.2 WARRANTY

A. The manufacturer shall guarantee in writing that the equipment furnished is appropriate for the intended service and shall be free of manufacturing and fabrication defects in material and workmanship for a period of one (1) year commencing from the date of Final Completion and acceptance.




A. To ensure unity of responsibility, the complete pump unit, including pump, base, coupling, and motor, shall be supplied, tested, and warranted by the manufacturer. The pump, base, coupling, and electric motor shall be factory assembled at the pump manufacturer’s facility.



WATER PLANTS

VERTICALLY MOUNTED


C. The manufacturer shall have a quality management system in place and shall be ISO 9001 certified.


2.1 GENERAL

A. Pumps shall be a vertically mounted, long coupled, single stage, double suction horizontal split case design of cast iron and bronze fitted construction suitable for chlorinated potable drinking water applications.

B. Pumps shall meet the operating conditions as specified in the Pump Schedule included in Appendix A at the end of this Section.


A. The Owner wishes to standardize pumping equipment at all of their facilities.

B. All pumping equipment shall be PACO model KPV as manufactured by Grundfos CBS Inc., 902 Koomey Road, Brookshire, Texas 77423. No product substitutions will be allowed.

2.3 PUMP DESCRIPTION

A. Pumps shall have the casing divided on the horizontal centerline. The casing halves shall be accurately machined, bolted and doweled together. A non-asbestos type gasket material shall be furnished between the casing halves. The casing material shall be close-grained cast iron ASTM A48 - Class 35 with a minimum tensile strength of 35,000 P.S.I. Pumps shall be fitted with lead-free bronze renewable case wear rings indexed with a dowel pin for fixed positioning. Removal of the upper casing half and bearing housings shall permit removal of the complete rotating assembly without disturbing piping connections. Volute shall have integrally cast support feet, gauge ports at nozzles, and vent and drain ports. Pumps with larger than 4-inch discharge flanges shall be of the double volute design extending to both upper and lower half of the casing. Casings shall be designed for scheduled working pressure and shall be hydrostatically tested at 150% of the maximum working pressure under which the pump could operate at design speed. Suction and discharge flanges shall be drilled to ANSI B16.1 Standards and be machined flat face. Flanges shall be extra heavy-duty design and will be of Class 250 thickness while capable of being drilled for Class 125 flat face use.

B. Pumps shall be provided with removable bearing housings which will permit inspection and/or replacement of the mechanical seals, shaft sleeves, and bearings without removing the rotating assembly or upper half of the casing. Straightening vanes shall be cast in both the bearing housings and casing to reduce pre-rotation of fluid prior to entry into the impeller.

A. The bearing housing shall be removable and supply support for heavy-duty single row grease lubricated ball bearings, with provision for purging or flushing if desired. The pump shaft shall be adequately supported by the pump bearings to limit the shaft deflection to 0.002 inches. Bearings shall be ball type, grease lubricated and locked to the shaft with positive locks of ample size to withstand any axial or radial thrust loads. Where grease lubricated bearings are utilized, a deflector made of aluminum shall be provided on the ends of the pump shaft to prevent product from entering bearing housings. Each bearing housing shall be bolted to the upper and lower casing halves for a full 360-degree support registered fit to insure positive alignment. Bearings shall provide a minimum L10 life of 10 years in accordance with the standards of the Bearings Manufacturers Association throughout the specified operating range of the pump.


WATER PLANTS

VERTICALLY MOUNTED


C. The pump shaft shall be of solid, stainless steel AISI 316 with stainless steel AISI 416 sleeves covering the wetted area of the shaft.

D. The pump manufacturer shall recommend the proper mechanical seal based on the pressure, temperature and liquid outlined on the equipment schedule. Mechanical seals, at a minimum, shall have ceramic stationary seats, carbon rotating seats, Buna elastomers and stainless steel hardware. Application of a mechanical seal shall be internally flushed type, without requiring external flushing lines. Seals shall be capable of being inspected and easily replaced without removing the upper half of the casing. The pump should be available with an option of no mechanical seal at the bottom, for easy maintenance.

E. Impeller shall be of the enclosed Francis Vane type, double suction design, made of aluminum bronze, ASTM B148 UNS 95400, both hydraulically and dynamically balanced to ISO 1940-1:2003 balance grade G6.3 and keyed to the shaft. The impeller shall be locked in position by threaded shaft sleeves. The impeller shall be trimmed to meet the specific hydraulic requirements.

F. A coupling, capable of absorbing torsional vibration and of operating in variable speed applications, shall be employed between the pump and motor.

G. The pump shall be supported from below by a cast iron mounting stand, which shall be bolted directly to the bottom of the casing. Supporting the casing from the side or top shall not be required, nor allowed.

H. The pump(s) vibration limits shall conform to Hydraulic Institute ANSI/HI 1.1-1.5, section 1.4.6.1.1 for recommended acceptable unfiltered field vibration limits (as measured per HI 1.4.6.5.2, Figure 1.108) for pumps with rolling contact bearings.

I. Pump rotation shall be clockwise or counter-clockwise as viewed from the pump’s motor end.

J. Standard Pump Construction. The standard material of construction for the pump shall be as below.

1. Casing: Cast iron, ASTM A48 – Class 35 2. Case wear ring: Lead-Free Bronze, ASTM B584-90500 3. Impeller: Aluminum Bronze ASTM B148 UNS 95400 4. Shaft: Stainless Steel, AISI 316 5. Shaft Sleeve: Stainless Steel, AISI 416 6. Mechanical Seals: Carbon–Ceramic with Buna elastomers and stainless steel hardware 7. Bearings: Grease lubricated heavy-duty ball bearing

K. Pump shall be of a maintainable design for ease of maintenance and should use machine fit parts that are easily disassembled.

L. Pumps shall be NSF-61 certified.

2.4 MOTORS

A. Pump and motors shall be factory laser aligned, and shall then be laser realigned after installation by the manufacturer’s representative. Manufacturer’s representative shall provide certification that installed pump and motor have been laser aligned meeting all manufacturer’s tolerances and requirements.


WATER PLANTS

VERTICALLY MOUNTED


B. Motors shall be suitably sized per ISO5199 and shall meet NEMA specifications and conform to the standards outlined in EISA 2007.

C. Motor shall be of the horsepower and speed shown in the Pump Schedule in Appendix A. Pumps requiring larger horsepowers shall not be acceptable. Pump shall be close coupled to a 3-phase, 60 Hertz, 480 volt, horizontal, TEFC motor with 1.15 service factor. 40°C ambient.

D. Motors shall be in conformance with the requirements of Section 16222, AC Electric Motors - 100 HP and Below.

2.5 PUMP COATINGS A. The Pump Supplier shall prepare all carbon steel and cast iron surfaces by blast cleaning, per SSPC-SP10, to a near white finish to achieve a surface anchor profile of 2 to 3 mils per ASTM D4417. All surfaces shall be shop prime painted with a coating compatible with the finish coating system specified herein.

B. All interior carbon steel or cast iron surfaces of the pump casing or other surfaces in contact with the pumped liquid shall be shop painted with a NSF Standard 61 approved two part epoxy coating, such as Carboguard 891 or Tnemec N140 Pota-Pox Plus, applied in two coats of 4 to 6 mils dry film thickness (DFT) each. Final DFT shall be 10 to 12 mils. Final color shall be white.

C. All pump exterior carbon steel and cast iron surfaces, including pump support base, shall be shop finish coated in accordance with Specification Section 09928.

D. Factory applied fusion bonded epoxy (FBE) is an acceptable alternative.

E. Apply coatings in accordance with the coating manufacturer’s latest published technical data sheets, application sheets and MSD sheets.

F. Stainless steel or bronze surfaces shall not be painted. Coat machined, polished, and non-ferrous metal surfaces and similar unpainted surfaces with corrosion prevention compound which shall be maintained during storage and until equipment begins operation.

2.6 NAMEPLATES

A. Nameplates and other data plates shall be of stainless steel, suitably secured to the pump.







WATER PLANTS

VERTICALLY MOUNTED






3.2 FACTORY TESTING AND CERTIFICATION

A. Each pump shall undergo a certified hydrostatic test at 150% of the pressure developed at shut-off head.

B. A certified performance test shall be performed on each unit utilizing its specified drive.



E. The Engineer and/or a representative of the Owner shall be given four (4) weeks’ notice of the testing dates and shall have the opportunity to witness these tests.

3.3 INSTALLATION


B. Services of the manufacturer’s factory representative shall be provided for a minimum of two (2) 8-hour days onsite for installation assistance, inspection, testing, start-up and training. At least two (2) separate trips shall be made, one during the installation period and the second during the inspection, testing, start-up and training period. All costs, including travel, lodging and meals, shall be included in the Contractor’s bid. Costs for additional days onsite required due to problems associated with installation issues or problems with delivered equipment shall be borne by the Contractor at no additional compensation to the Contract.


A. Equipment assembled, installed, and painted by the Contractor shall be approved by the both the manufacturer's factory representative and the Owner’s representative.



WATER PLANTS

VERTICALLY MOUNTED






END OF SECTION


WATER PLANTS

VERTICALLY MOUNTED


APPENDIX A

PUMP SCHEDULE

WP 06 PUMP LIST


(HP)NOMINAL FLOW

(GPM)TDH (FT)

STATUS

WP06-1-SCV 5012-7/8 KPV 6" / 5" 60 1,000 125 PROPOSED





OVERLOADING

CAPACITY(GPM)

1,000 1,255 500 1,600 0 1,805

TDH (FT)

125 116.3 134.1 99.1 136.5 85.7

PUMP EFFICIENCY(%)

82.8 85.1 61.6 80.7 - 73.2

POWER(HP)

38.1 43.3 27.5 49.6 - 53.3

MAX SPEED(RPM)

1,780 1,780 1,780 1,780 - 1,780

NPSHr(FT)

7.6 9.7 4.9 15.2 - 21.5

WP 20 PUMP LIST


(HP)NOMINAL FLOW

(GPM)TDH (FT)

STATUS






OVERLOADING

CAPACITY(GPM)

1,000 1,343 500 1,700 0 1,914

TDH (FT)

140 128.7 148.5 110.7 150.7 96.6

PUMP EFFICIENCY(%)

81.7 85.4 59.4 81.3 - 74.2

POWER(HP)

43.3 51.1 31.5 58.4 - 62.9

MAX SPEED(RPM)

1,780 1,780 1,780 1,780 - 1,780

NPSHr(FT)

7.6 10.7 4.9 17.9 - 26.2


WATER PLANTS

VERTICALLY MOUNTED


BLANK PAGE


WATER PLANTS

PUMP REFURBISHMENT

11400-1

SECTION 11400

PUMP REFURBISHMENT



A. Requirements for refurbishing and reinstalling existing pumps, performing performance verifications tests, submittals, shop tests, and field tests. Contractor shall install pumps in accordance with manufacturer’s recommendations and drawings.

1.2 WARRANTY

A. The manufacturer shall guarantee in writing that the equipment and materials furnished is appropriate for the intended service and shall be free of manufacturing and fabrication defects in material and workmanship for a period of one (1) year commencing from the date of Final Completion and acceptance.




A. To ensure unity of responsibility, the materials used for refurbishment of existing pumps shall be supplied, tested, and installed by the original pump manufacturer’s certified pump representative. The refurbished pump, base, coupling, and electric motor shall be factory assembled at the pump manufacturer’s facility.



WATER PLANTS

PUMP REFURBISHMENT

11400-2


2.1 GENERAL

A. Refurbished pumps shall meet the operating conditions as specified.

2.2 EXISTING PUMPING EQUIPMENT

A. All existing pumps are PACO pumps as manufactured by Grundfos CBS Inc., 902 Koomey Road, Brookshire, Texas 77423.

2.3 PUMP REFURBISHMENT WORK SUMMARY

A. Water Plant 14

1. Replace existing 40 HP motors and pump bases with new 50 HP motors and pump bases on two (2) existing horizontally mounted, close coupled end suction pumps (WP14-1-ESH and WP14-2-ESH). Existing PACO pump model is 40129LC. 2. Contractor shall modify existing pump base or provide new pump base to accommodate new motor and install per manufacturer’s installation requirements. Submit shop drawings on modified or new pump base. Pump manufacturer shall certify that pump base and installation meets their requirements.

B. Water Plant 20

1. Remove two (2) existing 60 HP horizontally mounted, split case pumps from Water Plant 20 for refurbishment and relocation to Water Plants 21 and 22. See requirements in 2.3.C and 2.3.D below. 2. Existing pumps are PACO pump model 4015-7/8 KP rated at 1000 gpm at 173 feet TDH at 1780 rpm.

3. Perform inspection of existing impellers. If in good condition, reuse and install in Pumps WP21-2-SCH and WP21-3-SCH. Trim to required diameter to meet Water Plant 21 duty point. See 2.3.C for additional requirements.

C. Water Plant 21

1. Relocate and install one (1) existing pump and 60 HP motor from Plant 20 (now known as WP21-3-SCH). 2. Existing pumps are PACO pump model 4015-7/8 KP rated at 1000 gpm at 134 feet TDH at 1780 rpm.

3. Proposed pump duty point for all three pumps is 1000 gpm at 134 feet TDH at 1780 rpm.

4. Perform shop pump flow test to determine impeller diameter required to meet Water Plant 21 specified duty point. 5. If impellers salvaged from pumps in Water Plant 20 are in poor condition, replace impellers with new impellers and install in Pumps WP21-2-SCH and WP21-3-SCH. New


WATER PLANTS

PUMP REFURBISHMENT

11400-3

impellers or salvaged impellers from Water Plant 6 pumps shall be trimmed to required diameter to meet proposed Water Plant 21 duty point. 6. For existing Pump WP21-1-SCH, provide new impeller trimmed to required diameter to meet proposed Water Plant 21 duty point.

7. Existing motors for Pumps WP21-1-SCH and WP21-2-SCH are 50 HP. If pump flow test indicates larger impellers are required to meet duty point, 60 HP motors may need to be provided to meet duty point and non-overloading conditions. Provide certified curves verifying horsepower requirements for non-overloading conditions for every point on the pump curve. Provide new 60 HP motors if required.

8. At a minimum, pump refurbishment shall include replacement of seals, shaft sleeves, wear rings, and hardware for pumps requiring impeller changes.

9. Inspect pump shaft and replace if in poor condition.

10. Provide three (3) new spare impellers, maximum diameter.

D. Water Plant 22

1. Relocate and install one (1) existing pump and 60 HP Motor from Plant 20 (now known as WP22-3-SCH). 2. Existing pumps are PACO pump model 4015-7/8 KP rated at 1000 gpm at 192 feet TDH at 1780 rpm.

3. Proposed pump duty point is 1000 gpm at 173 feet TDH at 1780 rpm.

4. Perform shop pump flow test to determine impeller diameter required to meet Plant 22 specified duty point. 5. For relocated Pump WP22-3-SCH, provide new impeller trimmed to required diameter to meet proposed Water Plant 22 duty point.

6. Inspect existing impellers on Pumps WP22-1-SCH and WP22-2-SCH and replace if in poor condition. If existing impellers are in good condition, reuse and trim to required diameter to meet proposed Water Plant 22 duty point.

7. At a minimum, pump refurbishment shall include replacement of seals, shaft sleeves, wear rings, and hardware for pumps requiring impeller changes.

8. Inspect pump shaft and replace if in poor condition.

9. Provide three (3) new spare impellers, maximum diameter.


WATER PLANTS

PUMP REFURBISHMENT

11400-4

2.4 BEARINGS

The bearing housing shall be removable and supply support for heavy-duty single row grease lubricated ball bearings, with provision for purging or flushing if desired. The pump shaft shall be adequately supported by the pump bearings to limit the shaft deflection to 0.002 inches. Bearings shall be ball type, grease lubricated and locked to the shaft with positive locks of ample size to withstand any axial or radial thrust loads. Bearings shall provide a minimum L10 life of 10 years in accordance with the standards of the Bearings Manufacturers Association throughout the specified operating range of the pump.

2.5 SEALS

The pump manufacturer shall recommend the proper mechanical seal based on the pressure, temperature and liquid outlined on the equipment schedule. Mechanical seals, at a minimum, shall have ceramic stationary seats, carbon rotating seats, Buna elastomers and stainless steel hardware. Application of a mechanical seal shall be internally flushed type, without requiring external flushing lines. Seals shall be capable of being inspected and easily replaced without removing the upper half of the casing.

2.6 IMPELLERS

Impeller shall be of the enclosed Francis Vane type, double suction design, made of aluminum bronze, ASTM B148 UNS 95400, both hydraulically and dynamically balanced to ISO 1940-1:2003 balance grade G6.3 and keyed to the shaft. The impeller shall be locked in position by threaded shaft sleeves. The impeller shall be trimmed to meet the specific hydraulic requirements.

2.7 MOTORS

A. Pump and motors shall be factory laser aligned, and shall then be laser realigned after installation by the manufacturer’s representative. Manufacturer’s representative shall provide certification that installed pump and motor have been laser aligned meeting all manufacturer’s tolerances and requirements.

B. New motors shall be suitably sized per ISO5199 and shall meet NEMA specifications and conform to the standards outlined in EISA 2007.

C. New motor shall be of the horsepower and speed shown in the Pump Schedule in Appendix A. Pumps requiring larger horsepowers shall not be acceptable. Pump shall be close coupled to a 3-phase, 60 Hertz, 480 volt, horizontal, TEFC motor with 1.15 service factor. 40°C ambient.

D. New motors shall be in conformance with the requirements of Section 16222, AC Electric Motors - 100 HP and Below.

2.8 NAMEPLATES

A. Provide new nameplates and other data plates of stainless steel, suitably secured to the pump.



WATER PLANTS

PUMP REFURBISHMENT

11400-5









3.2 FACTORY INSPECTION, TESTING AND CERTIFICATION

A. Provide inspection report noting all deficiencies and recommended refurbishment work and repairs.

B. A certified performance test shall be performed on each unit utilizing its existing drive.



3.3 INSTALLATION



A. Equipment assembled and installed by the Contractor shall be approved by both the manufacturer's factory representative and the Owner’s Designated Representative.



WATER PLANTS

PUMP REFURBISHMENT

11400-6





END OF SECTION


WATER PLANTS

VACUUM GAS CHLORINATION EQUIPMENT 11500-1

SECTION 11500

VACUUM GAS CHLORINATION EQUIPMENT

PART 1 - GENERAL


This specification includes all components, equipment and appurtenances involved with proposed vacuum gas chlorination systems.

1.2 WARRANTY

All components, equipment and appurtenances furnished under this section shall include a minimum one (1) year warranty from the date of substantial completion.


All materials and components shall be new and unused of first quality by well-known manufacturers. Inferior materials or components shall not be allowed.

PART 2 - PRODUCTS

2.1 GENERAL

A. New chlorination equipment shall be provided to modify the existing chlorine gas feed systems at each water plant. The new equipment is provided for post chlorination feed only.

B. Each chlorination system shall be a vacuum operated, solution feed, automatic, switchover type for dispensing chlorine gas from industry standard one hundred fifty (150) pound cylinders.

C. Each chlorination system shall have a chlorine gas feed capacity of not less than 50 pounds per day.

D. Each system shall convey the gas under vacuum from the cylinder mounted vacuum regulators to the ejector assemblies.

E. Each chlorination system shall automatically switch the gas supply from an empty cylinder to a full one.

F. Each system design shall permit the entire system to be vacuum checked in the field without the use of special tools.

G. Each system shall be constructed of materials suitable for wet or dry chlorine gas service. Vacuum regulator inlet valve springs shall be tantalum alloy.


A. Hydro Instruments, Telford, PA, USA (Vacuum Gas Chlorination Equipment)

B. Analytical Technology, Inc., Collegeville, PA, USA (Chlorine Residual Analyzer)

2.3 VACUUM GAS CHLORINATION

A. Cylinder Mounted Vacuum Regulators

1. Vacuum regulators shall mount directly on the gas cylinder valve by means of a corrosion resistant and gasketed yoke assembly complying with the standards of The Chlorine Institute, Inc. Vacuum Regulators shall be Hydro Instruments Series 800.

2. The inlet adapter shall be constructed of corrosion resistant Hastelloy C material.


WATER PLANTS


3. The vacuum regulator body parts shall be constructed of solid machined PVC material for maximum cracking resistance.

4. Each regulator shall have a spring-opposed diaphragm that controls vacuum and closes tight upon loss of vacuum.

5. Each regulator shall incorporate a pressure relief (vent) valve with separate ports for chlorine feed and chlorine vent. Automatic switchover vacuum regulators, which compromise safety by having a single exit port for vent and feed and rely on a detent mechanism and external pressure relief (vent) valve, shall not be acceptable.

6. Connections shall be provided for tubing vented gas away from the pressure relief (vent) port of each vacuum regulator to atmosphere outside the building. The outside end of the vent tubing shall be equipped with an insect screen.

7. Each regulator shall be equipped with an inlet filter to remove particulate matter from the gas before it enters the inlet safety valve.

8. Each regulator shall include a flow meter tube to indicate feed rate and which cylinder is in use.

9. Flow meter tubes shall indicate from rates up to 50 PPD and down to a minimum of 1/20 of the maximum value.

10. Each regulator shall include a mechanism to indicate when the cylinder is empty and requires replacement.

B. Automatic Switchover Module

Existing automatic switchover modules at each water plant shall be reused in the modified chlorination systems.

C. Automatic Control Valve – Wall Panel Mounted

1. General

a. The automatic control valve shall be provided to control 50 PPD of chlorine gas feed. The wall panel mounted automatic control valve shall be Hydro Instruments model WPOV-110 with control valve model OV-110 Omni-Valve

b. The automatic control valve shall be comprised of a PID controller and variable area orifice rate valve. These devices shall be incorporated into one compact unit.

c. The microprocessor based automatic control valve shall adjust the gas feed rate based on up to three analog input signals or by means of one to four 12-24 VDC inputs.

d. The automatic control valve shall allow for the following standard, field selectable control modes:

1) Manual

2) Proportional control (Flow)

3) Set-Point control (Residual/ORP)

4) Compound Loop control (PID)

5) Step-Feed control

6) Dual Input Feed Forward control

7) Dual Set-Point control


WATER PLANTS


e. Motion of the valve shall be achieved by means of a linear stepper motor.

f. Motion control shall be achieved without the use of a feedback potentiometer.

g. To ensure accurate feed rates throughout the range of operation, the software shall incorporate a 10-point valve linearization calibration.

h. The automatic control valve shall be capable of remote communication using the Modbus RS-485 standard.

2. Construction

a. The automatic valve shall be housed in a NEMA4X rated enclosure.

b. Materials of construction shall be of the finest available for the appropriate chemical.

c. For accurate feed rate control, the length of the variable area orifice portion of the rate valve stem shall be no less than 1.5 inches.

d. The automatic valve shall be installed onto a ½” thick polypropylene panel suitable for wall mounting.

3. User Interface

a. The automatic control valve shall include a 2-line, 20-character, alphanumeric, LCD display.

b. User controls shall be through a front panel 4-button keypad.

c. Menus and variables shall be displayed in plain English words using easy to read, alphanumeric characters for clear understanding.

d. Control mode and all control parameters shall be password protected and adjustable through the keypad while displayed on the screen.

4. Inputs and Outputs

a. The automatic control valve shall include three analog input channels.

b. Each analog input signal shall be independently user selectable as either 4-20mA or 0-10V.

c. The first input channel shall be used only for proportional (flow) input signals. The second input channel shall be used only for set point (residual or ORP) input signals. The third input channel shall be used for one of the following:

1) Remote adjustment of dosage

2) Remote adjustment of set-point

3) Remote valve positioning

4) Additional input for Dual Set-Point control

d. Four 12-24 VDC inputs shall be provided. These inputs can be used for:

1) Step-Feed control

2) External control of AUTO or MANUAL modes

3) External control of DUTY or STANDBY modes


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e. Two relay outputs shall be provided for remote indication of alarm conditions or indication of whether the valve is in AUTO or MANUAL mode. The use of these relays are user adjustable.

f. Two 4-20 mA output signals, proportional to the chemical feed rate, shall be provided.

g. The automatic control valve shall have a half-duplex, two wire interface type connection for Modbus RS-485 communication.

5. Remote Meter Panel

a. One (1) remote meter panel shall be provided to indicate the gas flow rate. The gas flow meter shall be suitable for wall mounting.

b. The gas flow meter shall be equipped with a control valve for manual feed rate adjustment and be constructed entirely of materials suitable for maximum chemical resistance and maximum service life.

c. The flow meter tube shall indicate flow rates up to 50 PPD and down a minimum of 1/20 of the maximum value.

6. Bypass Assembly

a. The automatic control panel shall be provided with a bypass piping and valve arrangement to allow for the selection of automatic feed control or bypass (manual) feed control. The selection of manual feed control shall isolate the OV-110 Omni-Valve.

b. The bypass piping arrangement shall be constructed of socket welded schedule 80 PVC pipe and pipe fittings.

c. The three (3) bypass valve shall be constructed with seals of suitable material for the specific chemical application.

D. Injector

1. Injectors shall be water operated Venture nozzle type. The injector shall provide the operating vacuum for the chlorination system.

2. The injector shall incorporate a spring loaded, normally closed check valve to prevent the backflow of water into the chlorine gas equipment. The check valve shall be suitable for back pressures up to a minimum of 140 psi.

3. Injector check vlave shall automatically close upon the loss of vacuum in the injector.

4. At a backpressure of 28 psi, a minimum water supply of 6.5 gpm at 50 psi at the injector inlet shall be required for 50 PPD capacity. Injectors shall be Hydro Instruments model no. CNH-012-191.

E. Vacuum Gas Chlorination System Accessories

1. PE gas tubing and Kynar compression fittings

2. Corp Stop Injection Quill Assembly (3/4” solution tube)

3. Pressure gauges with pressure snubbers and isolation valve

4. Inline Gas Check Valve, PVC

5. Vent outlet screens

6. Emergency kit for 150 lb. chlorine cylinders

7. Standard installation and spare parts kit and tools.


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2.4 CHLORINE RESIDUAL ANALYZER

A. On-line Chlorine Residual Analyzers shall be provided to continuously measure (specify free or combined chlorine residual) where stated in Section 2.5, Scope of Supply. Each Chlorine Residual Analyzer shall consist of a direct measuring chlorine sensor, a clear constant-head flowcell, 25 feet of sensor interconnect cable with quick disconnect plug, and an electronic monitor housed in a NEMA 4X enclosure suitable for wall, pipe, or panel mounting.

B. The chlorine sensor shall be a direct measuring polarographic sensor utilizing a special polymeric membrane to isolate the sensing electrodes from the sample and eliminate the potential for electrode contamination. The membrane shall allow chlorine to diffuse into the sensor where it shall react with the sensing electrode, generating a signal that is linearly proportional to chlorine concentration. The sensor assembly shall also contain a precision RTD temperature sensor to continuously measure sample temperature to allow temperature compensation of the measured chlorine value. The chlorine sensor shall be constructed with a quick disconnect receptacle to allow easy sensor servicing or exchange.

C. Chlorine sensors shall be supplied complete with at least 10 spare membranes, electrolyte, and a spare parts kit that includes all o-rings and special hardware.

D. The flowcell assembly supplied with the monitor shall be constructed of clear material allowing the condition of the sensor membrane to be inspected without removal of the sensor. The sensor shall slide easily into the side of the flowcell, with a double o-ring seal to prevent water leakage. Flow to the sensor shall be regulated automatically through a constant-head overflow arrangement. Hose barbs for sample inlet (1/4" I.D. tubing) and drain (1/2" I.D. tubing) shall be supplied as part of the flowcell.

E. The instrument shall be powered by 90-260 VAC single-phase line power and shall provide two isolated 4-20 mA outputs configurable for chlorine, pH temperature, or PID control. Analog outputs shall be both ground isolated and isolated from each other. Both versions shall also contain three SPDT relays.

F. The chlorine monitor electronic assembly shall provide a variety of functions as follows.

1. Provide user selectable display of PPM chlorine, process temperature, or PID % output on the main display. Main display variable shall be indicated with a minimum character height of 0.75” to allow easy readability up to 20 feet away.

2. Allow selection of operating ranges of 0-200 PPB, 0-2 PPM, 0-20 PPM, or 0-200 PPM. Display ranges shall be configurable by operators, or the monitor may be configured for Auto-Ranging. The auto-ranging function shall automatically switch to the display range that provides the best resolution for any given operating level.

3. Provide automatic pH correction of the measured free chlorine level based on input from an optional pH sensor. The pH compensation may be enabled or disabled by the user, and the pH value at which the correction factor is disabled (comp. stop value) may also be programmed by the user.

4. Provide the ability to use the 4-20 mA output for PID control. Proportional, Integral, and Derivative functions shall be user adjustable, and also provide for output hold when needed.

5. Provide two isolated 4-20 mA outputs, with output spans programmable by the user for any segment of a display range. When supplied with a pH sensor input, one 4-20 mA output may be assignable to the pH measurement to allow simultaneous output of both free chlorine and pH. An optional third analog output is available, providing separate outputs for chlorine, pH, and temperature.


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6. Provide output hold and output simulate functions to allow for testing or remote receiving devices or to allow maintenance without disturbing control systems.

7. Provide three 6 amp SPDT relay outputs in standard unit. Software settings for relay control include setpoint, deadband, phase, delay, and failsafe. Provide an optional 3-relay card, for 0-30 V signals, to bring the total to 6 relays. Relays shall be programmable for either control or alarm function, or relays may be assigned to diagnostic functions for use in indicating trouble conditions at a remote location.

8. Provide option for digital communications. These options shall include Profibus-DP, Modbus, or Ethernet.

9. Diagnostic functions shall be incorporated into the transmitter. The 4-20 mA output shall be capable of being assigned to safely rise to 20 mA, fall to 4 mA, or be left alone, during diagnostic failures. Diagnostic error messages shall be displayed in clear language; no confusing error codes shall be displayed.

G. The complete chlorine monitor shall be supplied with spare parts and accessories for up to 2 years of operation. A minimum of 10 replacement membranes shall be supplied for the sensor.

H. The complete Chlorine Residual Analyzer shall be Series Q46H-62-1-1-3-3-2-3 as manufactured by Analytical Technology, Inc.

2.5 SCOPE OF SUPPLY – NEW EQUIPMENT

Post-Chlorination System

Item Plant 6 Plant 14 Plant 15 Plant 20 Plant 21 Plant 22 Total No. Cylinder Mounted Vacuum Regulators, 50 ppd (Series 800)

4 4 4 4 4 4 24

Automatic Feed Panel (WPOV-110)

1 1 1 1 1 1 6

Ejector, 50 ppd (CNH-012-191)

1 1 1 1 1 1 6

Cl2 Residual Analyzer (ATI Q46H/62)

1 1 1 1 1 1 6

Corporation Stop Injection Quill (3/4” Solution Tube)

1 1 1 1 1 1 6

Accessories (per section 2.3.E)

1 1 1 1 1 1 6


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PART 3 - EXECUTION


Contractor shall provide storage for chlorination system equipment and materials in accordance with the manufacturer’s recommendations.

3.2 INSTALLATION, START-UP AND TRAINING

Install the equipment as shown on the drawings and in accordance with the manufacturer’s instructions. Manufacturer shall provide the services of a factory trained and authorized service representative to inspect and calibrate the system upon project start-up. Service shall be coordinated between the Contractor and Owner’s Designated Representative. Submit manufacturer’s field service report and start-up certification following completion. Manufacturers’ recommended spare parts shall be supplied on all equipment.

END OF SECTION


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BLANK PAGE


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PRECAST CONCRETE BUILDING 13122-1

SECTION 13122

PRE-CAST CONCRETE BUILDING

PART 1 - G E N E R A L

1.01 SUMMARY

A. Basis of Design: Contractor to furnish pre-cast, post-tensioned concrete building. Building to be field erected on level, contractor furnished, poured-in-place floor slab in accordance with design drawings (by others). Pre-cast building to be EASI-SET brand Model 305018 as manufactured by Lonestar Prestress Mfg., Inc., Houston, Texas or approved equal. Building to be provided by manufacturer with all necessary openings as specified in conformance with manufacturer's structural requirements.

1.02 CODES, STANDARDS AND REFERENCES

A. ACI-318-05, “Building Code Requirements for Structural Concrete”. B. ASCE-7-05, “ Minimum Design Loads for Buildings and Other Structures”.

C. 2009 IBC, “2009 International Building Code”.

D. PCI Design Handbook, Precast/Prestressed Concrete Institute. 6th Edition.

E. “Manual of Standard Practice”, Concrete Reinforcing Institute.

F. ASTM, American Society for Testing and Materials:

1. C150 - Standard Spec. for Type I and Type II – Low Alkali Portland Cement. 2. C33 - Standard Spec. for Concrete Aggregates.

3. A36 - Standard Spec. for Carbon Structural Steel.

4. A615 - Standard Spec. for Deformed and Plain Billet-Steel Bars for Concrete

Reinforcement.

5. A706 - Standard Spec. for Low-Alloy Steel Deformed and Plain Bars for Concrete Reinforcement.

6. A416 - Standard Spec. for Steel Strand, Uncoated Seven-Wire for Prestressed

Concrete.

7. A185 - Standard Spec. for Steel Welded Wire Fabric, Plain, for Concrete Reinforcement. 8. A307 - Standard Spec. for Carbon Steel Bolts and Studs, 60,000 PSI Tensile Strength.

9. A123 - Standard Spec. for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products.


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10. A153 - Standard Spec. for Zinc Coating (Hot-Dip) on Iron and Steel Hardware. 1.03 QUALITY ASSURANCE

A. Building fabricator must have a minimum of 10 years of experience manufacturing pre-cast

concrete buildings.

B. Fabricator must be a producer member of the National Precast Concrete Association (NPCA).

C. No alternate building designs will be allowed unless pre- approved by the owner TEN (10) days prior to the bid date.

1.03 DESIGN REQUIREMENTS

A. Dimensions:

Exterior: 30' x 50' x 19’-8”

Interior: 28'-11" x 48'-11" x 18’-1/2”

B. Standard Design Loads:

1. Standard Wind Loading - 100 MPH (ASCE 7-05, Category II, Exposure C, Enclosed Building)

2. Standard Roof Live Load - 20 PSF (with crane live load).

3. Standard Floor Live Load - 250 PSF

4. Seismic Design category ‘D’, Seismic Importance Factor, I=1.0.

C. Roof: Roof panel shall slope 9” in 15’-0”direction from peak to edge. The roof shall extend a minimum of 4" beyond the wall panel on each side and have a turndown design which extends 3/4" below the top edge of the wall panels to prevent water migration into the building along top of wall panels. Roof shall also have an integral architectural ribbed edge.

D. Keyway Roof Joints: Grout in keyway shall be polymer concrete placed after coating keyway

with a methyl methacrylate resin and isocyanate resin.


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E. Foundation (poured-in-place floor slab by contractor): There shall be a 1-1/2” deep by 10”

recess cast into the perimeter of floor slab except at doorways. The 1-1/2” recess makes the interior floor surface 1-1/2” higher than the joint between the wall panel and floor slab preventing intrusion of water. Building manufacturer will provide wall anchors at time of erection of panels.

F. Walls to be of an insulated precast concrete sandwich panel type. The walls shall have an

extruded polystyrene core sandwiched between interior and exterior concrete wythes. The wall panels shall have a minimum thickness of 6”. Minimum wythe thickness shall be 2”. The walls shall have a minimum required thermal performance (R-value) of R-26 (2003 IECC, Zone 2, 1,500 – 1,999 Heating Degree Days).

1.04 SUBMITTALS

A. Building engineering calculations that are designed and sealed by a professional engineer, licensed in the state of manufacture, shall be submitted for approval.

B. Building exterior stain shall be submitted for City approval.

PART 2 - PRODUCTS

2.01 MATERIALS

A. Concrete: Steel-reinforced, 6000 PSI minimum 28-day compressive strength.

B. Reinforcing Steel: ASTM A615, grade 60 or ASTM A185, grade 80 unless otherwise indicated.

C. Post-tensioning Strand: Roof shall be post-tensioned in field after keyway is filled and has cured to required strength (psi). Post-tensioned cable shall be 41K Polystrand CP5O, .50 in., 270 KSI, 7-wire ungreased strand (ASTM A416). There will be a minimum of five post-tensioning cables connecting roof and floors together to provide watertight joint.

D. Sealant: All joints between panels shall be sealed on the exterior and interior surface of the

joints. Sealant shall be SIKAFLEX-IA elastic sealant or equal. Exterior sealant joint to be 3/8" x 3/8" square so that sides of joint are parallel for correct sealant adhesion. Back of joint to be taped with bond breaking tape to ensure adhesion of sealant to parallel sides of joint and not the back.

E. Panel Connections: All panels shall be securely fastened together with 3/8” thick steel brackets. Steel is to be of structural quality, hot-rolled carbon complying with ASTM A36 and hot dipped galvanized after fabrication. All fasteners to be 1/2" diameter bolts complying with ASTM A307 for low-carbon steel bolts. Cast-in anchors used for panel connections to be Dayton-Superior #F-63, or equal. All inserts for corner connections must be secured directly to


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form before casting panels. Floating of connection inserts will not be allowed.

2.02 ACCESSORIES

A. Door and Frame: Shall comply with Steel Door Institute "Recommended Specifications for Standard Steel Doors and Frames” (SDI-l00), and as herein specified. The building shall be equipped with (1) 3'-0" x 7'-0" x 1-3/4" and (1) 4'-0" x 9'-0" x 1-3/4", 18-gauge steel doors, with 3-hour fire rating. Frames shall be 16-gauge steel. Field paint doors and frames with epoxy paint.

B. Door Hardware:

1. Handle: Lindstrum pull-handle stainless steel, 8-1/2” x 2”, or passage knob or equal.

2. Lockset: Cal-Royal lever lock or Easi-Set or equal.

3. Deadbolt: Yale or Easi-Set stainless steel keyed outside only or equal.

4. Hinges: Hagar stainless steel five knuckle ball bearing with non-removable pins or equal.

5. Threshold: Hagar or National Guard Products extruded aluminum with neoprene seal

or equal.

6. Overhead Door Holder: Yale surface mounted overhead slide type with safety release or equal.

7. Drip Cap: Hager or National Guard Products aluminum with stainless steel screws or

equal.

8. Door Closer: Norton 7500 or Yale 4410 with hold open or equal.

9. Door Frame: Prep door frame for electric access control provided by owner. Coordinate with City’s preferred security contractor, Knight Security, Larry Broyles, 832-786-5870.

C. Windows:

1. Provide Kawneer Trifab 451 with 1” insulated glass unit assembly or approved equal.

Install with a maximum 1/8” max variation across the opening and provide sealant and backer.

2.03 FINISHES


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A. Interior of Building: Smooth steel form finish on all interior panel surfaces. Some form marks and seams may be visible. Marks or seams that protrude more than 1/8” shall be ground down and sacked. Paint all interior wall and ceiling surfaces with white epoxy paint.

1.1 Exterior of Building: Architectural precast concrete brick finish: Finish must be imprinted in top face of panel while in form using an open grid impression tool similar to "EASI-Brick". Finished brick size shall be 2 5/8" x 7 5/8” with vertical steel float or light broom finish. Joints between each brick must be 3/8" wide x 3/8" deep. Back of joint shall be concave to simulate a hand tooled joint. Each brick face shall be coated with tile following acrylic concrete stain: 1) Cementrate by FOSROC; or 2) Canyon Tone stain by United Coatings. Stain color shall be brick red unless specified otherwise. Stain shall be applied per manufacturer's recommendation. Joints shall be kept substantially free of stain to maintain a gray concrete color. As noted on drawings.

PART 2 - E X E C U T I O N

2.1 DELIVERY, STORAGE & HANDLING

A. The building shall be stored on dunnage placed at the proper locations to prevent cracking, distortion, or any other physical damage.

B. The building shall be shipped F.O.B. jobsite by the Manufacturer. It shall be provided with Burke lifting fixtures for lifting and setting the building without incurring damage to the walls or roof.

C. The Building Manufacturer shall provide all cables and lifting hardware for use in off-loading and setting the building.

2.2 WARRANTY

A. The Manufacturer shall warrant the building and its components for one year from the date of installation.

B. The precast concrete structure shall endure and not deteriorate for a period of twenty-five (25) years.

END OF SECTION


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INSTRUMENTATION AND CONTROL GENERAL PROVISIONS 13400-1

SECTION 13400

INSTRUMENTATION AND CONTROL GENERAL PROVISIONS



A. This section includes the requirements for the provision of general instrumentation and control requirements for the City of Conroe Southwest Regional Wastewater Treatment Plant Wastewater Treatment Plant.

B. The requirements outlined in this section address general hardware, software, and system services necessary to provide the specified control functions. More detailed requirements of specific functions and components are presented in other sections that follow.

1.2 DEFINITIONS

A. Where the word “provide” appears in these specifications, it shall be construed to mean “furnish and install complete and ready for safe and regular use.”

B. The definitions of terminology used in the specifications shall be as defined in ISA Standard 51.1 unless otherwise specified. Where terms used are not defined in ISA 51.1 or in these specifications, IEEE Standards Dictionary: Glossary of Terms & Definitions, ISA S50.00.1 or other ISA standards shall apply.

1. Signal Circuit. Any analog circuit whose principal purpose is the conveyance of information and not the conveyance of energy for the operation of an electrically powered device. 2. Control Circuit. Any digital circuit whose principal purpose is the conveyance of information and not the conveyance of energy for the operation of an electrically powered device. 3. Power Circuit. Any circuit whose principal purpose is the conveyance of energy for the operation of an electrically powered device. 4. Two-Wire Transmitter. A transmitter which derives its operating power supply from the signal transmission circuit and, therefore, requires no separate power supply connections. As used in this specification, two-wire transmitter refers to a transmitter which provides a 4 to 20 milliampere current regulation of signal in a series circuit with an external 24-volt direct current driving potential and a maximum external circuit resistance of 600 ohms. 5. Electrical Isolation. Pertaining to an electrical node having no direct current path to another electrical node. As used in this specification, electrical isolation refers to a device with electrical inputs and/or outputs which are galvanically isolated from ground, the device case, the process fluid, and any separate power supply terminals; but such inputs and/or outputs are capable of being externally grounded without affecting the characteristics of the device or providing a path for circulation of ground currents. The terms “galvanic isolation,” “electrical isolation,” “isolation,” or similar terms shall mean electrical isolation whenever used in the specifications for electrical control and instrumentation equipment. Unless otherwise specified, electrical isolation for analog signal devices shall be in accordance with ANSI/IEEE C39.5. 6. Panel. An instrument support system which may be a flat surface, a partial enclosure, or a complete enclosure for instruments and other devices used in process control systems. Unless otherwise specified or clearly indicated by the context, the term “panel” in these contract documents shall be interpreted as a general term which includes flat panels, enclosures, cabinets and consoles.


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7. Data Sheets. Data sheets, as used in this specification, shall comply with the requirements of ISA 20. 8. Field. Locations external to a panel or piece of equipment where a field device is connected. 9. Control Room. An environmentally controlled area intended for housing control equipment, computers, control panels, etc., and intended for those parts of a control system for which operator surveillance is required on a continuing basis. 10. UPS. Uninterruptible Power Supply. 11. HMI. Human-Machine-Interface. The control system hardware and software associated with providing the visual interface between system users and the control system. 12. PLC. Programmable Logic Controller. Field installed unit which monitors and controls devices, located within the plant. The PLCs contain all logic necessary to monitor and control the system process located at the PLC location. 13. SCADA. Supervisory Control and Data Acquisition. 14. RTU. Remote Terminal Unit. Similar to a PLC, except in a more compact form. 15. DCS. Distributed Control System.


This subsection references the latest revisions of the following standards. They are a part of Division 13 as specified and modified. In case of conflict between the requirements of this section and those of the listed standards, the requirements of this section shall prevail.

Standard Title

ANSI/NEMA ICS 6 Enclosures for Industrial Control and Systems

ISA 5.4 Instrument Loop Diagrams

ISA 20 Specification Forms for Process Measurement and Control Instrumentation, Primary Elements, and Control Valves

ISA 50.00.1 Compatibility of Analog Signals for Electronic Industrial Process Instruments

ISA 51.1 Process Instrumentation Terminology

1.4 WARRANTIES, MAINTENANCE, AND SUPPORT SERVICES

A. Warranty. The manufacturer shall provide an all-inclusive 2-year warranty. The submittal shall provide a contract specific warranty document as detailed in the specifications.

B. Software Maintenance. After system software or equipment has been placed in service and tested, the Owner may request reasonable additions, modifications and deletions, at no additional cost to the Owner, to control strategies, displays, database, and reports.

1.5 CONTRACTOR’S QUALIFICATIONS

A. Perform all work necessary to select, furnish, configure, customize, debug, install, connect, calibrate, and place into operation all hardware and software specified within this section and in other sections.


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B. Utilize the following “systems integrator,” who is regularly engaged in the design and the installation of instrumentation and control systems and their associated subsystems as they are applied to the municipal water or wastewater industry:

Prescott Control Solutions 4822 Gypsy Forest Drive Humble, TX 77346 Attn: Jeff Prescott, Project Manager 281-808-1642 Email: [email protected]

For the purposes of this specification section, “systems integrator” shall be interpreted to mean an organization that complies with all of the following criteria:

1. Employs a registered professional Control Systems Engineer or registered professional Electrical Engineer to supervise or perform the work required by this specification section. 2. Employs personnel on this project who have successfully completed a manufacturer’s training course on the configuration and implementation of the specific programmable controllers, computers and software proposed for this project. 3. Has performed work of similar or greater complexity on at least three projects within the last 5 years and has implemented and completed at least one of these three projects with the proposed HMI software. 4. Has been in similar industries performing the type of work specified in this specification section for at least 5 continuous years.

C. Maintain a fully equipped office/production facility with full-time employees capable of fabricating, configuring, programming, installing, calibrating, troubleshooting, and testing the system specified herein. Qualified repair personnel shall be available and capable of reaching the facility within 24 hours.

1.6 SUBMITTALS

A. General.

1. Submit to the Owner technical data and drawings for all equipment, materials, software, assemblies, and installations prior to fabrication and installation. In all instances in which submittals are required by the specifications, do not proceed with the associated work until the submittal has been Successfully Reviewed. 2. Each submittal shall be complete, with all required information provided together at one time, and submitted in a sequence that allows the Owner to have all of the information necessary for checking and approving a particular document at the time of the submittal. Plan and make all submittals as necessary to avoid delays or conflicts in the work.

B. Submittal Categories.

1. Project submittals are divided into the following general categories: a. Design Submittals. b. System Documentation Submittals. c. Testing Submittals. d. Training Submittals.

2. The following paragraphs define the specific contents of each of these submittal categories. The requirements outlined for each of these submittals shall apply to all equipment and services specified in the appropriate section of the specifications. Additional submittal requirements may be found in other sections of the specifications.


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C. Design Submittals.

1. Hardware Submittal. a. Product information shall include, but not be limited to: catalog cuts, data sheets, performance surveys, test reports, equipment lists, material list, diagrams, pictures, and descriptive material. The product information shall cover all items including mechanical devices, mounting components, wiring, terminal strips, connectors, accessories, and spare parts. The submittal information shall show product features, as well as all performance data and specifications. b. Prior to commencement of manufacture (or shipment for stock items), submit for review product information for all equipment and material specified in the specifications, or required to support equipment, or systems specified in the specifications. Specific requirements for the form and content of product information submittals are included in the individual section that defines the equipment requirements.

2. Connection Diagrams. Submit the following: a. Connection diagrams shall show the placement, labeling and wiring of components within panels, cabinets and consoles. Components shall be shown arranged in the physical layout (not necessarily to scale) as it would appear to a person servicing the equipment. Connection diagrams shall include all internal wiring of the panel and connections to external devices. This shall include AC and DC power wiring and multi-conductor cables from PLC I/O modules to the associated termination blocks. Wires shall be shown as a continuous line between their termination points. Each wire label designation shall be shown. The wire label designations on each end of a single wire must be identical. All wire termination point numbers shall be shown. Signal and DC circuit polarities shall be shown. All jumpers, shielding and grounding details shall be shown. b. Submit connection diagrams for all new panels, cabinets and consoles. c. Furnish drawings on paper, electronically as Adobe PDF files, and in the latest AutoCAD electronic format. Electronic files shall be submitted in CD or DVD format.

3. Panel Fabrication and Layout drawings. Submit the following: a. Panel fabrication drawings shall be drawn to scale and show the physical dimensions, materials, and construction of panels, cabinets, terminal boards, consoles, or other electrical or mechanical equipment enclosures. These drawings shall show the physical arrangement and mounting of all components in or on a panel, terminal board, cabinet, console, or enclosure, as well as the physical dimensions, and the space and mounting requirements of mechanical, electrical, control and instrumentation devices or pieces of equipment. Include ventilation requirements, locations of connections, weight, paint color, material and dry film thickness that are applicable to this design. b. Panel fabrication and layout drawings shall include a bill of materials; front, back, and section views; the locations of all components to be mounted in or on the panel, cabinet, console, enclosure or assembly; drawing scale; nameplate engraving schedule; and structural materials and supports. Overall dimensions and minimum clearances shall be shown. Sufficient detail shall be included to demonstrate material choices, outward appearance, construction methods, and seismic force resistance. c. Complete shop drawings shall be prepared and submitted for all panels, cabinets, and consoles which are custom fabricated or modified for this project. The Owner shall have the right to make modifications to the interior and exterior layouts of panels as part of the shop drawing review. d. Furnish drawings on paper, electronically as Adobe PDF files, and in the latest AutoCAD electronic format. Electronic files shall be submitted in CD or DVD format.

4. Interface Cables. Submit interface cable pin-out/cable makeup diagrams. This includes all network cables, radio to PLC/RTU cables, computer to PLC cables and printer cables. Submittal shall include copies of the actual hardware documentation. All cables shall either be standard


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cables from the manufacturer or custom-made. Custom cables must not require the use of gender changers, 9-25 pin converters, null modem adapters, etc., for them to function correctly. 5. Interconnection Diagrams. Submit cable interconnection diagrams. These interconnection diagrams shall include typical wiring diagrams for each type of product. Wires shall be shown as a continuous line between their termination points. Each wire label designation shall be shown. The wire label designations on each end of a single wire must be identical. All wire termination point numbers shall be shown. Each wire color shall be shown. Signal and DC circuit polarities shall be shown. All jumpers, shielding and grounding details shall be shown. 6. Installation drawings. Submit panel installation drawings. These panel installation drawings shall show installation arrangements for all provided equipment, mounting and anchoring details, conduit entries into cabinets, and control system electrical power supply distribution conduit and wiring. Data sheets and/or catalog cuts for mounting devices, anchors, wire and other incidental installation materials shall be included. 7. Software. Submit the following software documentation for review:

a. OEM Software. Submit the product data sheets for OEM software supplied under this contract. OEM software packages include HMI software, RTU/PLC configuration/programming software, reporting software (if not part of the HMI software), and other third-party software provided under this contract. b. Application Software. Application software includes the software and programming developed to implement the specific requirements of the drawings and specifications.

1) Submit functional design descriptions of the application software that implements the control strategies described in the drawings and specifications. These descriptions shall include field actions/interactions, control interlocks, sequencing, alarms to be generated, and operator interactions with the control strategy. 2) Submit fully annotated program listings for PLC/RTU programming showing but not limited to the following:

a) Custom programming provided. b) Communication Port configuration. c) I/O module configuration. d) System architecture. e) Field bus layout and configuration. f) Database layout and tag naming.

3) Submit color screen prints of custom graphic screens for the HMI and layout drawings for any field panel interfaces. This submittal shall also include a list of the symbols and color scheme for the presentation of the various data.

D. Operation and Maintenance (O&M) Manuals.

1. Supply O&M manuals for all the equipment and software provided. O&M manuals shall be developed for personnel at the level of electronic technician. O&M manuals shall describe the detailed preventive and restorative procedures required to keep the equipment in good operating condition. An O&M manual or a set of manuals shall be furnished for all deliverable hardware, including OEM equipment. O&M manuals for OEM equipment shall contain original printed materials, not copies, and may be provided in the manufacturer’s original format. Manuals shall be provided in electronic format. 2. Instruction Manual.

a. The manual shall be written in English and illustrated in detail to the component level, including assemblies, subassemblies, and components. It shall contain a detailed analysis of each major component so that maintenance personnel can effectively service, inspect, maintain, adjust, troubleshoot, and repair the equipment.


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b. Each manual shall include a Table of Contents, arranged in systematic order, and shall be divided into the following sections:

1) Introduction. The purpose of the manual, special tools and equipment, and safety precautions. 2) General Information and specifications. A general description of the equipment item and specifications of its major components. 3) Listings. Supplier’s name, address, and telephone number. Each product shall include name, address, and telephone number of subcontractor, or installer, recommended maintenance contractor, and local source for replacement parts. 4) Theory of Operation. The relationship of assemblies, subassemblies, components and interchangeability of components, and explanation and analysis of their functions to the smallest board replaceable components. 5) Software. Listing and explanatory text for any software or firmware. 6) Operation Procedures. The locations and functional descriptions of all controller indicators or CRT displays. 7) Troubleshooting. A list in tabular format of all symptoms, probable causes of malfunction or improper operation, and probable remedies to the smallest board replaceable components.

3. Preventive Maintenance Instructions. These instructions shall include all applicable visual examinations, hardware testing, and diagnostic hardware/software routines. Instructions on how to load and use any test and diagnostic programs and any special or standard test equipment shall be an integral part of these procedures. 4. Corrective Maintenance Instructions.

a. These instructions shall include guides for locating malfunctions down to the card-replacement level. These guides shall include adequate details for quickly and efficiently locating the cause of an equipment malfunction and shall state the probable source(s) of trouble, the symptoms, probable cause, and instructions for remedying the malfunction. These guides shall explain how to use on-line test and diagnostic programs for all devices and any special test equipment, if applicable. b. The corrective maintenance instructions shall include:

1) Explanations for the repair, adjustment, or replacement of all items, including printed circuit cards. Schematic diagrams of electrical, mechanical, and parts location, illustrations, photographs, and sectional views giving details of mechanical assemblies shall be provided as necessary to repair or replace equipment. Typical signal waveforms, logic levels, bit patterns, etc., shall be included. For mechanical items requiring field repair, information on tolerances, clearances, wear limits, and maximum bolt-down torques shall be supplied. Information on the loading and use of special offline diagnostic programs, tools, and test equipment, as well as any cautions or warnings which must be observed to protect personnel and equipment, shall be included. 2) A list of test equipment and special tools required. 3) A list of all abbreviations and circuit symbols used. 4) Warranties, bonds and maintenance records, including proper procedures in the event of failures and instances which might affect the validity of warranties, bonds, or contracts. 5) A parts catalog enumerating every part to the lowest of card replaceable components. The description shall include component symbol, description, ratings, accuracy, manufacturer’s name and address, manufacturer’s part number, commercial equivalents, and quantity per assembly or subassembly. The parts catalog shall identify the appropriate locations of the parts and shall group each component by assemblies or subassemblies within each subsystem so that each component can be identified as being part of the next larger assembly.


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6) A list of recommended spare parts that includes all parts necessary to maintain and repair control system components. The list shall identify the specific part or model number, description, manufacturer’s name and address, commercial equivalents, unit price, lead time for delivery, and recommended quantity. The spare parts list shall indicate which components (by model and serial number) have been provided with the delivered system as part of the spares inventory.

5. Drawings. a. O&M Manual drawings (with the exception of those provided by third-party manufacturers) shall not be larger than 11 inches by 17 inches and shall be clearly legible when reproduced using conventional office copying machines. Originals shall be provided for all third-party O&M Manual materials. One reproducible of the O&M Manual drawing original must be supplied for each O&M Manual drawing larger than 11 inches by 17 inches, and must satisfy all drawing requirements specified herein. Those preprinted O&M Manual drawings which are not acceptable, or which must be modified or corrected to show the actual as-built design, shall be redrawn as new specially-prepared shop drawings. Acceptable equipment manufacturer’s drawings incorporated into equipment operating and maintenance manuals need not be duplicated or removed from the manuals. b. Furnish drawings on paper, electronically as Adobe PDF files, and in the latest AutoCAD electronic format. Electronic files shall be submitted in CD or DVD format. c. Each O&M Manual shall be bound in 8-1/2-inch by 11-inch, 3-ring side binders with commercial quality hardback, cleanable plastic covers. Maximum of 3-inch binder size. An electronic copy of the O&M Manual shall be submitted in CD or DVD format. d. Binder covers shall contain the printed title:

OPERATION AND MAINTENANCE INSTRUCTIONS CITY OF CONROE

2014 SURFACE WATER SYSTEM IMPROVEMENTS WATER PLANTS

e. The manuals shall be internally subdivided with permanent page dividers with tab titling clearly printed under reinforced laminated plastic tabs. f. Each volume shall have a Table of Contents, with each product or system description identified.

6. Software Manuals. Supply original OEM O&M manuals for those standard OEM software packages provided under these drawings and specifications. Supply O&M manuals for the application software developed for these contract documents.

E. Record Documents.

1. After successful Site Demonstration Test, submit for review the Record Documents (as-built) for all equipment and software installed by the Contractor. All documents which have changed because of the engineering changes, contract changes, or error or omission shall be updated and the revised documentation provided. 2. Furnish complete as-built sets of:

a. Source tapes, disk pack(s) or other storage media for all custom programs. b. Loadable and executable object disk pack(s) of the software systems. c. All previously delivered documents, with as-built updates. d. OEM standard documentation.

3. These media shall include the operating systems, all programs necessary for the operation as well as maintenance of the system, and all programs supplied by the CPU/microprocessor manufacturers, such as assembler, loaders, editors, compilers and diagnostics. 4. The documentation as outlined in this portion of the document, in conjunction with other documentation specified elsewhere in this document, shall be sufficient to allow the Owner to reconfigure or make additions or deletions to the system without assistance from the Contractor.


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F. Testing Documentation Submittals. Submit testing plans to meet the requirements listed in Part 3 - Execution of this section and the subsequent reports resulting from the testing. The following paragraphs describe the general content of each submittal.

1. System Test Plan. The system plan describes the overall system testing. As a minimum, the plan shall include the general objectives of the test; the delineation of responsibilities of the Owner, Engineer, and Contractor during the test; any initial coordination issues; the location of the testing; a general description of each phase of testing or subsystem test; a description of the expected results; and a description of the procedures for the tracking of the test procedures, as well as any issues and problems that might result from the testing. This plan does not list the specific test procedures. 2. Test Procedures. This test plan is a document that lists the specific tests. Each test should include a description or listing of any setup requirements, the test procedure, and the expected results. 3. Test Reports. The test reports are the documents prepared during the actual testing. These reports shall also include any documentation of any problems and the resolution of those problems.

PART 2 - P R O D U C T S

2.1 INFORMATION ON DRAWINGS

A. Include the following information at a minimum on the drawings:

1. Loop diagram on flow sheet for each control loop. Diagrams are schematic in nature and intended only as a guide to work to be performed. 2. Approximate location of primary elements, instrument panels and final control elements. 3. Approximate location of instrumentation power junction boxes for instrument electrical power connection. 4. Location of electrical distribution panelboards for instrument electrical power. 5. Location of equipment having alarms and equipment status contacts. 6. Location of equipment being controlled by system. 7. General layout of instrument cabinets. 8. Instrument installation details.

B. The following information is not shown on drawings but shall be the responsibility of the Contractor to determine, furnish and coordinate with other Divisions, based upon systems specified. Show this information on project Record drawings.

1. Instrument loop drawings per ANSI/ISA S5.4 minimum, desired and optional items. 2. Location of electrical distribution panelboards supplying power to any device supplied under this contract. 3. Detailed enclosure and instrument panel layouts, fabrication details and wiring diagrams. 4. Detailed system configuration. 5. Raceway and cable routing for instrumentation wiring.

2.2 OPERATING CONDITIONS

A. Ambient Conditions. Provide equipment suitable for project ambient conditions specified. Provide system elements to operate properly in the presence of radio frequency fields produced by portable RF transmitters with output of 5 watts operated 24 inches from instruments; in the presence of


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plant telephone lines, power lines and electrical equipment; and in the presence of digital data transmission systems.

B. Field Locations. Field equipment may be subjected to ambient temperatures from -5 to 50°C with direct radiation, relative humidity from 0 to 100 percent with condensation.

C. Power Supply. Power supply will be 117 volts AC, single-phase, 60-hertz commercial power. Voltage variations will be at least plus or minus 8 percent. Ensure that analog signal loops incorporate adequate power supply capacity for operations.

2.3 TRANSIENT AND SURGE ISOLATION

Protect all power and communication and transmission/ receiving circuitry from any surge, including spikes up 1,000 volts peak and surges with a rise time of less than one microsecond. Use a combination of current limiting resistors, zener diodes, gas tube surge arresters, and a fusible link which melts and shorts the surge to ground before the device circuitry is affected. Provide protection adequate for personnel safety, which will prevent an erroneous output, change in calibration, or failure of component other than fuse or fusible link.

2.4 SPARE PARTS

When required spare parts are utilized during construction to correct a faulty condition, replace spare part in kind.

2.5 SPECIAL TOOLS

Supply one of each type of special hand tool required to open or operate equipment, to remove or replace replaceable parts, remove or replace cable connectors, or to make required operational or maintenance adjustments. A special hand tool is any tool not readily available from local retail hardware stores.

2.6 TEST EQUIPMENT

Provide a complete list of all tools, test equipment, and commercial software programs necessary for the proper maintenance of the system. This list shall contain the quantity recommended, model number, description, cost, and name and address of supplier.

2.7 MATERIALS AND EQUIPMENT

A. Materials. Material shall be new, free from defects, and of the quality specified. All instruments with the same specification shall be from the same manufacturer.

B. Equipment.

1. Provide equipment of solid-state construction utilizing semiconductors available from two or more sources, unless otherwise specified. Derate components to ensure dependability and long-term stability. Provide printed or etched circuit boards of glass epoxy, hand or wave soldered, of sufficient thickness to prevent warping. Where indicated, printed circuit boards in field-mounted equipment shall be covered with a conformal coating to protect against corrosion. Alignment and adjustments shall be non-critical, stable with temperature changes or aging, and accomplished with premium grade potentiometers or electronically with settings stored in non-volatile memory. Do not insert components of specially selected values into standard electronic assemblies to meet performance requirements. Use parts indicated in instruction manuals, replaceable with


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standard commercial components of the same description without degrading performance of completed assembly. Use edge connectors and pins with phosphor bronze contacts with gold-plated mating area. 2. Use test equipment and instruments to simulate inputs and read outputs suitable for purpose intended and rated to an accuracy of at least five times greater than the required accuracy of device being calibrated. Test equipment shall have calibration traceable to NIST. 3. Equipment located in hazardous areas shall be suitable for applicable classification by use of either explosion-proof housings or by equipment and barriers being approved as “intrinsically safe” by either UL or FM. Locate barriers in cabinets outside the hazardous area. Use dual barriers in loops in order to prevent grounding loop at the barrier.


3.1 SPECIAL PROJECT REQUIREMENTS

A. Coordinate with all the sub-systems suppliers and manufacturers, during bidding, construction, testing, installation and start-up phases of the project. The coordination is to assure that the instruments, and sub-systems are in compliance with the specifications and the central controls, and that the tie-ins and the interface signals are provided as required.

B. The calibration, testing and start-up of all the instruments shall be done by the manufacturer's field technician/engineer in the presence of the Owner. Provide a list of all manufacturers whose technician will perform this work. Provide a certified calibration report stating that each instrument has been installed per manufacturer’s recommendations and per these specifications.

3.2 SYSTEM DESIGN

A. Provide all the necessary hardware, software and program development to satisfy the instrumentation and control system described in the contract documents.

B. Prepare design submittals for 30, 60 and 90 percent design levels for review by the Owner. These design submittals shall be in accordance with the Submittals article of this specification.

C. Configure and program the control system to meet the functional and performance requirements of the contract documents. This shall include the development of:

1. System point input/output list. 2. Control logic to implement the control strategies described in the contract documents. 3. Configuration and programming of the field units with the control logic. 4. System database and point naming (tagging) conventions. 5. Development and implementation of custom operator interfaces and screens. 6. Configuration and implementation of the system reporting to include alarm configuration and reporting. 7. Design, configuration, and any programming of the system communication network.

D. Install, connect, tune and perform all necessary startup of the system in accordance with the contract documents.

E. Perform all system testing described in the System Test Requirements article of this section.

3.3 INSTALLATION AND STARTUP


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A. Install the new equipment in accordance with the drawings and specifications.

B. Coordinate with the Owner to keep the Owner processes operating during the installation and cutover phases of the project. Any outages required shall be requested in writing with the Owner and approved at least 24 hours prior to the start of the outage.

C. Provide any temporary power and/or controls necessary to keep the Owner’s processes operating during the installation of the new equipment.

D. Coordinate any startup testing of new equipment with the Owner prior to the actual testing. Startup testing is defined as any Contractor test to verify to the Contractor’s satisfaction that the new equipment has been installed in accordance with the manufacturer’s recommendations and the drawings and specifications. Testing shall not be a substitute for the formal testing listed under Article 3.4, System Test Requirements of this specification.

3.4 SYSTEM TEST REQUIREMENTS

A. General Requirements.

1. The control system shall undergo a comprehensive system test process to demonstrate that the system performs as an integrated unit to meet the requirements of this specification. As a normal course of system development, conduct all element, subsystem, and system tests necessary to ensure the proper operation of the control system at various stages of system development. This type of testing normally will not be witnessed; however, the Owner and Engineer reserve the right to witness these tests if concerns arise about the progress of system implementation. 2. Three formal, witnessed tests shall be conducted on the control system:

a. Factory Demonstration Test. b. Field I/O Point Checkout. c. Field or Site Acceptance Test.

3. The following paragraphs describe the requirements for each of these formal tests.

B. Factory Demonstration Test (FDT).

1. The FDT and verification for all equipment, software, and associated documentation shall be performed prior to system, subsystem, or major components shipment. The tests shall be performed to verify that the equipment is manufactured and assembled correctly, is operating as designed, and is in compliance with the contractual documents. The tests shall be performed to verify also that the software and hardware will meet the functional and performance requirements of the contract documents. The Owner and the Engineer will witness these factory tests. The supplier of the control system shall provide the following for the Owner and the Engineer.

a. Notification 4 weeks in advance of the tests. b. Air travel to/from the test facility and Waco Regional Airport. c. Lodging in a hotel. d. Ground transportation. e. Meals. f. If retesting must be performed to obtain satisfactory results, items b through e shall be at Contractor’s expense for subsequent tests.

2. The FDT shall demonstrate compliance to the stated requirement in the specification. Use the approved Factory Demonstration Test plan submitted under Article 1.6 of this specification.


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3. The FDT shall include the following: a. Equipment Test and Verification. The FDT for the equipment (hardware) test and verification shall include individual end-item verification and integrated tests of all hardware. These tests shall include visual inspection verification and running the standard hardware diagnostic programs, plus all special diagnostic programs used by the Contractor to demonstrate that the hardware integration task has been completed. b. System Functional Test. The FDT for the system functional test shall exercise every specified system function and shall include, but not be limited to, the following:

1) Rigorous exercising of all devices both individually and collectively. 2) Verification of proper scanning and data acquisition of status and data points. 3) Demonstration of all redundant functions and components. 4) Demonstration of all required data base management functionality. 5) Demonstration of all required software support utilities. 6) Demonstration of all system diagnostics, both on-line and off-line.

c. Project Application Software Tests. The FDT for the project application software shall demonstrate to the best extent possible, the proper functioning of the application control logic implementing the control strategies for this project. These tests shall include:

1) Control logic response to both field inputs, operator changes, and any interlocks. 2) System event and alarming. 3) Trending of variables. 4) System reporting. 5) System redundancy.

d. Support Software Tests. The FDT for the support software shall include the following, as a minimum:

1) Demonstration of system editing capabilities including the addition and deletion of points in a PLC; the addition, deletion, and modification of HMI displays; the addition, deletion and modification of report formats; the addition, deletion, and modification of control strategies; and the modification of the database and all database parameters. 2) Demonstration of the editing of all system parameters including timers, intervals, etc. 3) Demonstration of utility software facilities, including assembling, compiling, appending, downloading and uploading of programs. On-line programming and debug facilities shall also be demonstrated.

C. Field I/O Point Checkout.

1. An I/O point-to-point test shall be performed after all equipment is shipped and installed in the field. This is an end-to-end test to verify that the equipment has been installed correctly. 2. The Owner and the Engineer will witness these field tests. 3. The I/O point checkout shall demonstrate the proper operation of all the field points affected by the installation of the equipment provided by this contract. 4. Provide a printed I/O list for all signals to be monitored and controlled under this contract with sign-off space, space for test results and space for notes for each signal. 5. The I/O point checkout shall include, but not be limited to, the following:

a. Exercise each discrete input. Each state shall be verified at the field unit and the operator workstation. b. Exercise each analog input. Each input shall be verified at 0, 25, 50, 75, and 100 percent range of the instrument. Linearity of the signal shall be verified. Each value shall be verified at the field unit and operator workstation.


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c. Exercise each discrete output. Each state shall be initiated from the operator workstation. If necessary, the associated equipment shall be placed into a “safe” state such that the activation of the output will not damage the equipment or cause a safety hazard. d. Exercise each analog output. Each output shall be verified at 0, 25, 50, 75, and 100 percent range of the instrument. Linearity of the signal shall be verified. Each value shall be initiated and verified at the operator workstation. e. Unless constrained by the operation of the plant or due to safety reasons, all testing, except for the analog input tests, should include the actual equipment and not use simulated signals.

D. Field or Site Acceptance Test.

1. Conduct a site acceptance test to demonstrate the proper implementation, installation and startup of the control system logic and software using the actual devices and plant equipment. 2. Conduct this test in accordance with the approved test plan submitted under Article 1.6 of this specification. 3. This test shall include, but is not limited to, the following:

a. Demonstrate the communication between the local operator interfaces and field units. b. Demonstrate communication between the control room and field control units. c. Demonstrate any peer-to-peer communication. d. Demonstrate the ability to upload, modify and download control logic to field control units. e. Demonstrate that the control logic and programming has been installed and implemented in accordance with the project control strategies and contract documents. This test shall demonstrate this on a subsystem, then system-wide basis. f. Demonstrate the plant equipment responds properly to operator commands. g. Demonstrate any plant interlocks function properly and in accordance with control strategies and contract documents. h. Demonstrate system reporting and proper report formats. i. Demonstrate system event and alarming functions in accordance with the approved design and contract documents. j. Demonstrate trending of system points both real time and historical. k. Demonstrate system redundancy.

3.5 TRAINING

A. Conduct the following training:

1. Operator Training. a. The objective of operator training is to provide the Owner’s operational personnel with the knowledge necessary to properly use the new equipment to perform their day-to-day duties as plant operators. b. A combination of classroom and field training shall be provided, as required to sufficiently comply with all training requirements. In general, training shall be limited to one 8-hour day, unless otherwise necessitated to sufficiently complete required procedures outlined herein. c. Operator training shall utilize the project O&M manuals as a basis for this training. d. Submit to the Owner a course outline or syllabus and training material for the topics to be covered in operator training. e. Operator training shall occur prior to the system being placed into operation.


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f. As a minimum, operator training shall include but is not limited to: 1) Operation of the plant and process equipment from HMI equipment in the main control room and any remote control areas. 2) Operator response to alarms and feedback displays. 3) Trending of system variables. 4) HMI screen navigation functions. 5) Types of HMI control functions used and the operation of each (i.e. radio buttons, sliders, data entry points, etc.). 6) General functioning of the communication network. 7) Graphic screen d 8) isplays in the HMI (i.e. types, information displayed on each, etc.). 9) Alarm (acknowledging and alarm history) and event functions. 10) Reporting functions (configuring, scheduling, and running reports).

2. Maintenance Training. a. The objective of maintenance training is to provide the Owner’s maintenance personnel with the knowledge necessary to properly perform maintenance activities on the system to include preventive and corrective maintenance. b. A combination of classroom and field training shall be provided, as required to sufficiently comply with all training requirements. In general, training shall be limited to one 8-hour day, unless otherwise necessitated to sufficiently complete required procedures outlined herein. c. Wherever possible, the Owner’s maintenance personnel shall be involved in the startup and testing of the system in order for them to get oriented to the system. d. Maintenance training shall utilize the project O&M manuals as a basis for this training. e. Submit to the Owner a course outline or syllabus and training material for the topics to be covered in maintenance training. f. As a minimum, maintenance training shall include but is not limited to:

1) Preventive and maintenance schedule(s) shown in the O&M manuals. 2) General functioning of the communication network and troubleshooting of communication errors. 3) Functioning of field equipment, instruments, and HMI equipment. 4) Use of any diagnostic software provided with the system. 5) Use of any special tools provided with the system. 6) Instrument calibration procedures and schedules.

B. The Contractor has the option of utilizing manufacturer training personnel to meet the requirements of the operator and maintenance training.

END OF SECTION


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PROGRAMMABLE LOGIC CONTROLLERS (PLC) 13410-1

SECTION 13410

PROGRAMMABLE LOGIC CONTROLLERS (PLC)



A. This section includes the requirements for the provision of a complete and operational control system made up of Programmable Logic Controllers (PLCs), including hardware, software and installation in accordance with the contract documents.

B. Provide the PLC hardware for the locations and requirements identified on the drawings. This shall include all PLC hardware, software, cables, connectors, PLC/PC network interface cards, termination blocks, PLC data highway cable, PLC Ethernet equipment, and any other hardware and/or software to ensure a fully operational unit.

C. Provide installation services for the PLCs. This service shall include removing the existing hardware if applicable, installing new hardware, panel wiring, I/O points check, and testing.

1.2 SUBMITTALS

A. Product Data.

1. Submit vendor specification information for each scheduled device specified in this section. 2. Submit vendor specification information for each material and unscheduled device specified in this section.

B. Provide two complete sets of as-built drawings for each PLC panel. These drawings shall be complete and accurate. If applicable, existing PLC improvement changes or modifications shall be shown on the as-built drawings. Each set of drawings shall be provided in both paper and electronic copy.

1.3 WARRANTY

The manufacturer shall provide an all-inclusive 2-year warranty. The submittal shall provide a contract specific warranty document as detailed in the specifications.

1.4 TRAINING

The manufacturer shall provide operating training and maintenance training as detailed in the specifications.

1.5 SPARE PARTS AND TOOLS

The manufacturer shall provide the specified spare parts and/or tools as detailed in specifications.


2.1 GENERAL REQUIREMENTS


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A. All PLCs shall be Schneider Electric SCADAPack 32. PLC I/O modules shall be selected within one I/O product family. No substitutions are allowed.

B. PLC hardware, power supply, CPU and I/O modules, shall fit in the specified panels. In all cases, verify that their PLC supplied will fit and operate properly in the space indicated on the drawings.

C. The PLCs shall be self-contained units capable of collecting data through electrically dry relay contacts, 4 to 20 mA DC analog, high level AC input signals, and contact making pulsing devices supplied by Owner. The PLCs shall also be capable of providing AC and DC control outputs, both momentary and latching, the contacts of which will be used by Owner for remote control. Provide all interposing relays that may be required to interface with the field AC signals.

D. The PLCs shall be fully programmable in a high level language and shall not require burning or etching of an EPROM for applications programs.

E. The PLCs shall have stand alone calculation and control capability to perform the control logic functions using software and setpoints downloaded from the HMI.

F. Provide a control power supply for the PLC system. The control power unit shall be installed in each PLC panel. The power unit shall be properly sized, installed, wired, checked and tested.

2.2 PLC DESIGN REQUIREMENTS

A. General.

1. Approved PLC manufacturers are: Schneider Electric SCADAPack 32. 2. The PLCs shall be solid-state electronic units of programmable design. The PLCs shall have a stand-alone restarting capability, i.e., no reloading of software programs for common logic, communications, and I/O processing at the PLC shall be required to resume operation following a loss of power. Therefore, all PLC basic programs shall be resident in battery backed up RAM with at least a five-year battery life or a solid state non volatile memory card from which the PLC can be rebooted. 3. Solid state RAM shall be utilized for data buffering, change of state information, calculation parameters, and local control algorithms. A power failure indication shall be reported to the HMI after recovery from a power failure so that status initializing may be initiated by the HMI. 4. All electronic components shall be mounted on plug-in printed circuit cards or modular subassemblies. Each printed circuit card and subassembly shall be model and serial numbered to uniquely identify it. Printed circuit cards shall be plug-in with quick disconnect field terminations. 5. As a minimum the PLC CPU board shall have LED’s for run, CPU fail, and low battery. The I/O modules shall have a power present LED. 6. Equipment shall be sufficiently sturdy to withstand handling during shipment, placement, and start-up without damage or distortion. 7. All switches and breakers and other current interrupting devices shall be non-arcing or hermetically sealed.

B. PLC Common Logic. Logic functions shall be implemented to receive data from and transmit data to the network, perform address decoding and error checks, and transfer data to and from the point input/output logic. In conjunction with the other PLC logic elements, the following functions shall be performed:

1. Respond to commands for retrieving data.


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2. Prevent selection of more than one control point in a command sequence. 3. Protect against single component failures causing a malfunction. 4. Inhibit relays from being energized erroneously during the initial power-up period of the PLC. 5. Provide a "power fail bit" which will be set upon commercial power loss or failure of the AC/DC power supply. 6. Protect against a missing or failed logic card causing a malfunction, damage to other logic, or false transmission to the HMI. 7. Protect against over/under voltage conditions from the Owner’s power source and/or the Contractor's power subsystem from causing malfunction, damage to logic, or false transmissions to the HMI. 8. Provide a "Change Summary" bit in the returned message to report status point changes on an exception basis (if all status is not returned on each scan). 9. Provide a real-time clock function. 10. Each PLC shall continually monitor its operation and shall shut down in case of failure that would cause faulty solution of logic. A running PLC shall identify communication failures, I/O assembly errors, I/O module errors, and CPU battery failure and shall report such faults to the HMI. Faults shall also be reported to the PLC test set whenever it is connected to a PLC. In addition, a PLC trouble alarm shall activate a discrete output if any diagnostic detects a failure or upon CPU failure. 11. Provide for Peer-to-Peer communication between PLCs. Use of the HMI servers to exchange the data is not acceptable. 12. Provide empty I/O modules with a door cover for all PLC empty slots.

C. PLC Hardware Requirements.

1. Shall communicate using Ethernet compliant to IEEE 802.3. 2. Shall communicate using an open standard, such as DeviceNet Ethernet/IP or ControlNet, for the PLC I/O network.. 3. No DIP switches shall be used in the PLC system. All I/O addressing shall be done in software and all module configuration details shall be supplied by the PLC controller. 4. Shall be capable of changing RAM battery without loss of program.

D. I/O Modules. The following types of process I/O interface capabilities shall be provided for the PLC:

1. I/O modules shall be capable of being removed or replaced under power while the controller is running so as not to disturb other operating elements of the PLC system. 2. I/O modules shall be software configurable. 3. I/O modules shall have the ability to define the failure mode of output modules. I/O modules shall be configured to turn all outputs off or zero (default state), go to predefined safe station, or hold the last value which the module received just prior to the watch dog timer expiration. This configuration information shall be set up on a point by point or channel by channel basis. 4. I/O modules shall have the capability of DeviceNet ControlNet or Ethernet/ IP communication by using a communication adaptor. 5. Discrete Input Requirements (DI).

a. Provide PLC interface with the status and alarm contacts. For the "dry" contacts, the PLCs shall sense the states of these contacts by applying a voltage and observing the extent to which current flows. This voltage shall be obtained from a separate, isolated power supply. The voltage applied across the Owner's open contacts shall be 24 VDC nominal.


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b. The exact input configuration shall be sized to meet the discrete input needs as specified on the drawings. The final configuration shall be from the standard product offering of the PLC manufacturer. c. The module shall contain at least 16 DI points, in four point groups.

6. Discrete Relay Output Requirements (DO). a. The discrete output logic shall process the control commands received from the common logic. Any control scheme, in which a single message with undetected errors can cause a false command, shall be unacceptable. b. Discrete output drive circuitry shall be designed such that any single logic component failure in the PLC does not energize a discrete output. c. The exact output configuration shall be sized to meet the discrete relay output needs as specified on the drawings. The final configuration shall be from the standard product offering of the PLC manufacturer. d. The module shall contain at least 16 DO relay points.

7. Analog Input Requirements (AI). a. Analog inputs from the transducers shall be 4-20 mA DC and all transducer power shall be provided by the dedicated 24 VDC + 10% power supply in the PLC Panel, or from an isolated output of the field device. The module shall be Bi-Polar with broken wire and Out of Range fault detection. b. The exact input configuration shall be sized to meet the analog input needs as specified on the drawings. The final configuration shall be from the standard product offering of the PLC manufacturer. c. The module shall contain at least 8 AI channels.

8. Analog Output Requirements (AI). a. Analog outputs shall be used to drive final control elements. Power shall be provided by the dedicated 24 VDC + 10% power supply in the PLC Panel. b. The exact output configuration shall be sized to meet the analog output needs as specified on the drawings. The final configuration shall be from the standard product offering of the PLC manufacturer. c. The module shall contain at least 8 AO channels.

E. PLC Power Supply. PLC power supplies shall be supplied with 24 V DC. PLC power supplies shall contain a “Power OK” LED.

F. PLC Communications. PLC Communications between the HMI servers and the PLCs shall be Ethernet compliant to IEEE 802.3. The transmission media for links that reside entirely within a building shall be fiber optic cables. For any links that leave the building and are exposed to the external environment, transmission media shall be fiber optic terminated directly within the PLC panel. Each module shall be configurable with a unique IP network address. The protocol for Ethernet communications is to be Ethernet/ IP as defined by ODVA. (ODVA.org).

G. Remote I/O. The PLC shall support remote I/O racks connected to the PLC via an open protocol. The Remote I/O rack shall utilize the same rack and power supply as the PLC. Provide prefabricated remote I/O drop cables and connectors from the PLC manufacturer.

2.3 PLC SOFTWARE REQUIREMENTS

A. The PLC shall be programmed to provide the overall system functions as described in the specifications, using software currently utilized by the Owner.

1. General Requirements. The following are the requirements for the PLC programming software package.


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a. Windows® Based. b. Be able to monitor and modify the PLC online. c. Contain a equation editor for complex algorithms. d. Have quick key support. e. Be compliant with IEC-61131 Ladder Logic, Function Block, Structured Text, and Sequential Function Chart program formats. f. Have on-line help menus.

B. Diagnostics and System Programming. The PLC shall be programmed to provide the basic system functions as described in the specifications. Specific functions which shall be performed via PLC-level software include, but are not limited to, the following functions:

1. PLC network configuration, including IP addressing. 2. CPU module configuration. 3. I/O module configuration. 4. I/O database download as provided by the Owner.

C. Provide two copies of the fully-licensed versions of the latest version of the PLC programming package.

D. The PLC Programming Software shall be the full version of package provided by the manufacturer. It shall include all the latest service packs provided for the programming package by the manufacturer with discs, manuals, certificates in original packaging. The software shall be licensed in the name of the Owner.

E. Make available to the Owner all updates provided by the manufacturer for any provided software during the warranty period.

2.4 PROGRAMMING CABLES

Furnish two programming cables for each type of PLC/RTU to be programmed.


3.1 TEST REQUIREMENTS

A. Factory Demonstration Test. The PLCs shall be integrated with the other components of the PLC system and tested as part of the system Factory Demonstration Test specified in the specifications. In addition to the general system test requirements, each PLC shall be subjected to the tests described in this section with a written confirmation of the test results.

B. Burn-In Test.

1. Provide certification that the PLCs meet the ambient temperature requirements and have been tested to screen for infantile failures. If this certification is not provided by the PLC manufacturer, conduct the following test. 2. All PLCs furnished shall be placed in a room having an ambient temperature of 60 degrees C with the PLCs connected to a data channel and to equipment simulating actual field equipment to be monitored or controlled. They shall remain energized at this temperature for a minimum period of 48 hours. During this 48-hour test period, the PLC shall have its various modes of operation exercised periodically. Any equipment failures shall be corrected and shall cause the test to be rerun in its entirety.


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C. PLC Functional Test. Each PLC shall successfully pass the following functional tests to be performed in conjunction with the system Factory Demonstration Test:

1. A close and open operation on each control point, showing proper sequence of operations 2. Verify the proper operation of the digital outputs 3. A test showing that the proper indications are given at a Operator Workstation when one or more status input points change momentarily 4. A series of communications tests showing all message protocols and formats to which the equipment is designed to respond, and demonstrating that all error-detection or error-correction capabilities function properly, and that the equipment does not respond to erroneous commands 5. Telemeter readings of selected analog points to verify that the readings are within the specified accuracy when the inputs are at 0, 25, 50, 75 and 100 percent of full-scale 6. A test showing that as a result of a scan request from the HMI, all requested analog, indication, and alarm points are transmitted from the PLC 7. A test showing that the PLC successfully performs its various modes of operation while the power source for the PLC is varied over its specified range 8. A test verifying that all common equipment, wiring, files, and power supplies are provided for expansion of the PLC to the ultimate point count specified. This test shall also verify that the power supplies are capable of carrying the increased load for this expanded point count. 9. A test to verify the proper operation of the stand alone capabilities of the PLCs. This shall include configuration of the loops or downloading from the HMI and testing the actual control strategy with test signals.

END OF SECTION


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Uninterruptible Power Supply 13412-1

SECTION 13412

UNINTERRUPTIBLE POWER SUPPLY



This section includes the requirements for the provision of complete Uninterruptible Power Supply (UPS) systems, including battery packs for the locations indicated on the drawings.

1.2 REFERENCES

A. ANSI.

B. NEMA.

C. UL.

D. NEC.

1.3 SUBMITTALS

Submit the following information to the Engineer for review:

A. Shop drawings and product data.

B. Installation instructions and wiring detail.

C. Supplier shall certify that the equipment furnished meets or exceeds the VA capacity requirements of this section.

D. Provide battery rack dimensions; battery type, size, dimensions and weight; detailed equipment outlines, weights and dimensions; single-line diagram indicating metering, control and external wiring requirements if required to meet the specified runtime.

1.4 WARRANTY

The manufacturer shall provide an all-inclusive two (2)-year warranty. The submittal shall provide a contract specific warranty document as detailed in the specifications.

1.5 TRAINING



The manufacturer shall provide the specified spare parts and/or tools as detailed in the specifications.


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2.1 SYSTEM RATING

A. The equipment shall be sized to maintain a system continuous rating for all connected equipment.

B. The UPS system shall be equipped with a battery. The battery shall be capable of supporting the load at rated voltage for a minimum protected period of 20 minutes.

2.2 ELECTRICAL CHARACTERISTICS

A. The system shall be designed for an input of 120VAC, single-phase, two-wire, at 60 hertz, with a 5% total harmonic distortion.

B. The system battery shall be capable of operating a full load.

C. The system shall be designed to deliver output voltage at 120VAC, single-phase, two-wire, 60 hertz, with output voltage regulation of plus or minus 3 percent when on inverter.

D. The overall system efficiency shall be 90% while line power is present.

E. The UPS shall be of a double-conversion (on-line) configuration with a hot-swappable battery replacement capability.

F. The UPS shall be tested in accordance with and comply with the surge voltage withstand capabilities defined in ANSI/IEEE C62.41 Category A & B, 6KV/200 & 500 Amp. 100kHZ ringwave.

G. The UPS output wave on battery voltage shall be a sine wave.

2.3 BATTERY

A. Batteries shall be sealed, maintenance-free lead acid with a 3-6 year typical lifetime.

B. Batteries should be located in thermally isolated compartments or in separate battery modules to minimize battery degradation from heat generated by the UPS.

C. Battery replacement design shall allow for hot-swap change-out of the battery packs without the necessity of turning off the UPS.

2.4 DESIGN AND CONSTRUCTION

A. The UPS shall be housed in a freestanding cabinet unless otherwise specified. Rack mount units may be specified in some applications.

B. Forced air cooling shall be provided to ensure all components are operated within their environmental rating.

C. Rectifier/charger capacity shall be sufficient to supply full load to inverter while recharging fully discharged battery to 60 percent of full capacity in four hours or less.


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D. The UPS shall have a front panel display that is capable of displaying the percentage of UPS capacity in use, the percentage of battery runtime available during an AC line power failure and displaying various status codes.

E. The UPS shall be provided with a software package capable of providing various real-time status and diagnostic functions.

F. The UPS shall be provided with dry-contact alarm contacts that indicates the status of the incoming power, and the health of the UPS. These contacts shall be connected to the local PLC for monitoring by the SCADA system.

G. Mean time between failures of 60,000 hours, minimum.

H. The audible noise level shall not exceed 60 db at 1 meter.

I. Electroplate brackets and securing hardware with corrosion resistant material. Secure bolts, studs and nuts with lockwashers.

J. Provide cabinet grounding lug.

K. Cabinet Finish. Primed and painted inside and outside with suitable semi-gloss enamel.

2.5 MANUFACTURER

Approved UPS manufacturers are:

A. Sola HD (www.solahd.com)

B. Powerware (www.powerware.com)

C. Liebert (www.liebert.com)

D. M G E (www.mgeups.com)


3.1 INSTALLATION

A. Install UPS where shown on the drawings and in accordance with manufacturer's instructions. Connect the alarm contacts to the digital inputs to alarm loss of power to the UPS, and failure of the UPS.

B. Perform field inspection and testing; verify performance criteria; measure battery discharge and recharge times; simulate fault in each system component and utility power.

END OF SECTION


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CONTROL PANELS 13413-1

SECTION 13413

CONTROL PANELS



A. This section includes the requirements for the provision of control panels as shown on the drawings, complete with power supplies, communications equipment, PLC/RTU Equipment, motor starters, variable frequency drives, pre-wired termination blocks, incoming power surge suppression, UPSs, and miscellaneous equipment to provide a fully functional system as shown on the drawings and specified herein.

B. This section also specifies the requirements for the provision of connection wiring within panel and electrical accessories such as switches, pilot lights, relays, terminal blocks, and fuses, which are included in the panel.

C. All work and products shall conform to the designs shown on the applicable drawings, and shall comply with the provisions of this section. All control panels shall be factory-wired. Panels and cabinets shall include all components indicated in the applicable drawings, required to provide functions as specified in this section. Where specific requirements on the drawings conflict with general design requirements in this section, the requirements shown on the drawings shall prevail.

1.2 REQUIRED PANELS

Panels shall conform to the requirements indicated on the drawings and specified herein and sized to accommodate the initial and future Input/Output (I/O) point counts.


All equipment and accessories provided shall be the product of a manufacturer regularly engaged in manufacturing of this equipment whose products have been in satisfactory service for not less than 3 years. Completed panels shall bear the UL label.

1.4 PANEL COMPONENT LAYOUT

Follow the arrangements of components shown on the drawings. Make adjustments as necessary to allow each component to be mounted as recommended by the manufacturer, to facilitate easy installation, removal and in-place maintenance of each component, and to allow normal operation of the component by operating and maintenance personnel. Component arrangements shall allow space for routing of wiring without kinking or bending around sharp edges, and for free flow of air around and through equipment, which requires ventilation for cooling.

1.5 WARRANTY

Provide an all-inclusive 2-year warranty for labor and materials.

1.6 TRAINING



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The manufacturer shall provide spare parts and/or tools required to perform standard maintenance for up to five years after acceptance


A. All materials and workmanship shall conform to the latest published applicable provisions of the following codes and standards:

Standards Title

ANSI/NFPA 70 National Electrical Code (NEC)

ANSI/NEMA ICS 1 General Standards for Industrial Controls and Systems

ANSI/NEMA ICS 2 Industrial Control Devices, Controllers, and Assemblies

ANSI/NEMA ICS 3 Industrial Systems

ANSI/NEMA ICS 4 Terminal Blocks for Industrial Control Equipment and Systems

ANSI/NEMA ICS 6 Enclosures for Industrial Controls and Systems

ANSI/NEMA 250 Enclosures for Electrical Equipment (1000 Volts maximum)

EIA RS-310-C Racks, Panels, and Associated Equipment

ANSI-C-37.13 Low-Voltage AC Power Circuit Breaker (600 Volt Insulation Class)

ANSI/IEEE-C-37.90-1 Standard for Surge Withstand Capabilities (SWC) Tests for Relays and Relay Systems Associated with Electric Power Apparatus

ANSI/IEEE C39.5

UL 508

UL 508A

Electrical Isolation for Analog Signal Devices

Industrial Control Equipment

Industrial Control Panels

B. Unless otherwise specified, electrical equipment and material provided under this contract shall be listed and labeled for the purpose for which it is used by the Underwriters Laboratories, Inc. (UL). This requirement may be waived only if a UL listing is not available for the type of product and approved by the Engineer.

1.9 SUBMITTALS


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A. General. Submit for all items supplied. For each panel, submit a certified factory (shop) test report prior to shipment of panels.

B. Product Data. Provide product data sheets for each item utilized.

C. Elementary Control Diagrams. Provide elementary control diagrams, using the ladder diagram format incorporating line number, operation function statement, contact location line number with an underline for a normally closed contact and a description of operation of each device. Label each contact, coil, and indicator with its function, as well as its number. Show terminals for field wiring. Show field wiring as dashed lines.

D. Panel Layout Drawings. Show the general arrangement of the equipment within the control panel. The view shall be from the front of the panel with an open door. Include any section views necessary to present a clear picture of equipment mountings and clearances.

E. Connection Diagrams. Provide connection diagrams which show the following:

1. Placement, labeling and wiring of components within panels and cabinets. 2. Components arranged in the physical layout (not necessarily to scale) as it would appear to a person servicing the equipment. 3. Wires as a continuous line between their termination points. 4. The direction of entry to a wire bundle. 5. Wire lists and wireless diagrams are not acceptable. 6. Additions and deletions of devices and wires in existing enclosures. 7. Each wire label designation. 8. Identical wire label designations on each end of a single wire. 9. Wire termination point numbers. 10. Each wire color. 11. Signal and DC circuit polarities. 12. Jumper, shielding and grounding details. 13. Wire pairs. 14. Spare wires and termination points.

F. Test Procedures. Submit Factory Demonstration procedures as required in the specifications.

G. Submit thermal calculations for all panels.


2.1 CONTROL PANELS

A. Physical and Miscellaneous Specifications. The enclosures shall:

1. Non-conditioned Spaces. NEMA 4X 316 stainless steel with 3-point latching handle. 2. Conditioned Spaces. NEMA 12 painted steel with 3-point latching handle. 3. Contain PLC/RTU equipment, surge arresters, circuit breakers, fuses, relays, transformers, terminal strips, nameplates, terminal labels, wire ducts, universal spiral wraps and any necessary parts for a complete systems as shown on the drawings and specified herein. 4. Be wall mount or free standing as appropriate for the application. 5. Allow expansion space to accommodate future system needs.


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2.2 PANEL FABRICATION

A. Materials. The enclosure shall be made with 14 gauge, minimum for wall-mounted units and 12 gauge, minimum for floor- or free-standing units. Each shall be provided with a full length interior panel(s) with adjustable mounting on both vertical sides to rails located at the top, bottom, and middle of the enclosure.

B. Acceptable Manufacturers.

1. Hoffman Engineering Company (www.hoffmanonline.com). 2. Rittal (www.rittal.com). 3. Approved substitution.

C. Dimensions. Panels shall be sized to accommodate all initial and 25% spare space.

D. Face-Mounted Instrument Reinforcement. Face-mounted devices shall be mounted to panel doors using mounting methods recommended by the component manufacturer with mounting kit parts provided by the component manufacturer specifically for the component. If such a mounting method causes the door to deform or allows the component to sag so as not to be perpendicular to the door surface, then design and install appropriate reinforcement to prevent these conditions. Addition of the face-mounted devices shall not compromise the rating of the enclosure.

E. Miscellaneous.

1. Face-mounted equipment shall be flush or semi-flush, with flat black escutcheons. Cutouts for future equipment and holes resulted from removal of existing devices shall be blanked off with suitable covers as required to retain the cabinet's NEMA rating. Component identification shall be hot ink stamped on the panel interior. 2. All miscellaneous hardware and fittings shall be 316 stainless steel, minimum.

2.3 NAMEPLATES

Machine engraved, three ply laminated phenolic nameplates shall be provided for all panels and cabinets as shown on the drawings. Nameplates shall be black with white lettering. Nameplates shall be attached to the panel with a minimum of two self-tapping 316 stainless steel sheet metal screws. The height of each character shall be a minimum of 3/16 inch, except as noted.

2.4 WIRING AND ELECTRICAL DEVICES

A. General. Provide electrical devices specified below and associated wiring to provide a fully functional control panel system.

B. Power Distribution.

1. Unless otherwise specified, power for instrumentation equipment shall be obtained from a 120VAC, 60 hertz branch circuit panelboard. 2. Each cabinet shall be equipped with a 120VAC main power disconnect circuit breaker and power distribution circuit breakers as shown on the drawings. Circuit breakers shall be sized in accordance with ANSI/NFPA 70 - NEC. Circuit breakers shall be rated at 250VAC with a minimum AIC rating of 10,000 amps. Mount circuit breakers on a standard DIN rail and be channel mounting type.


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3. For each power circuit breaker, a neutral return terminal block shall be installed at the bottom of the breaker rail. The neutral return terminal block shall be standard DIN-rail mounted, and shall be rated the same as the phase bus and accept up to two 12 AWG wires. This terminal block shall conform to the requirements specified herein. 4. Each cabinet shall be provided with grounding type receptacle power outlets for 120VAC power supply connections. Each piece of equipment equipped with an AC power cord shall be plugged into a power outlet.

C. Panel Connection Wire and Cable.

1. All cable furnished by the contractor, including cable with any and all wires terminated at both ends within the same panel or enclosure and cable with any wires terminated at more than one panel or enclosure, shall conform to the requirements specified below.

a. Power and Control Cable. Power and control wiring shall be single conductor stranded copper NFPA 70 Type XHHW. Power wiring from the main circuit breaker to distribution breakers shall be 12 AWG minimum. All other single conductor 120VAC and 24VDC power and common return wiring, common ground buses and all common logic bus circuits shall be 14 AWG minimum. Circuits protected by 20 Amp circuit breakers shall be 12 AWG minimum. All power wiring shall be rated for 600V and 90C. b. Single Conductor Wire. All single conductors used for logic, PLC/RTU input/output and discrete control circuit wiring shall be No. 16 AWG stranded conductor copper, Belden Type 9916 (0.092-inch O.D.), or approved substitution. c. Multi-conductor Foil-shield Cable (TP). All multi-conductor cable used for logic, PLC/RTU input/output and discrete control circuit wiring shall be No. 16 AWG stranded copper conductors with polyvinyl/chloride jacket. The cable shall be rated for a minimum of 600 volts and 80C. The cable shall have an overall aluminum/polyester foil shield with drain wire, Alpha XTRA-Guard 1, or approved substitution. d. Analog Signal Cable. Wiring for 4-20 milliampere, 1-5 volt DC signals and other analog signals shall be No. 18 AWG stranded copper twisted pair shielded cable, 80C rated, UL listed, 0.25 inches maximum outside diameter, with 100 percent coverage aluminum foil mylar-lines shield and No. 22 AWG (minimum) stranded tinned copper drain wire, Houston Wire and Cable, Belden, or approved substitution. Multi-pair analog signal cable shall be individually shielded (with drain wire) No. 18 AWG stranded conductor copper with a 100 percent aluminum/polyester foil shield with drain wire and an outer PVC jacket. The cable is designated TSP on the drawings. The cable shall be rated for 600V, 80C (NEC Article 300-3). e. Multi-Individual Conductor (TP). Multi-individual conductor cables used for logic, PLC/RTU input/output and discrete control circuit wiring shall be number 16 AWG stranded copper conductors with polyvinyl/chloride jacket . The cable shall be rated for a minimum of 600V and 80C. The cable shall be Belden, or approved substitution.

2. Wire Tagging. All panel connection wiring shall be tagged at terminations with machine printed slip on type tags. Show wire/cable tag designations on all wiring diagrams submitted to the Owner. There shall be a tag placed within two inches of any wiring termination. The tag shall be fixed to the wire to prevent the tag from sliding more than two inches from the terminal as the result of gravity and vibration. 3. Control circuit, logic bus and power circuit wires shall be tagged as follows:

a. Control Circuits. Each individual connection wire shall be tagged at both ends of the wire with a wire number. The tag shall be placed on the wire within two inches of the terminal to which the wire is terminated. Assign a unique number for each wire within a panel.


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b. Power Circuits. All 120VAC power wires shall be tagged with the designation "120VAC-" followed by the circuit breaker number shown on the drawings, then followed by a letter designating whether the wire carries the line (L), neutral (N) or power ground (PG). c. Positive 24VDC power circuit and power bus wires shall be tagged with the designation "+24VDC-" followed by the circuit breaker number shown on the drawings, and 24VDC power returns shall be designated with "24VDC COMMON".

4. Wire Colors. Control, logic bus and power conductors in panels shall have the following insulation colors:

Usage Color Line Power Black Neutral White Power Ground Green +24 VDC Panel Bus Blue +24 VDC Field Bus Orange 24 VDC Common Gray with Red

Stripe Control Red Foreign Voltage (voltage supplied by a source external to the panel)

Yellow

5. Signal Circuits. Signal circuit multi-conductor cables shall be tagged at each end with the designation shown on the wiring diagram. Each signal conductor shall be tagged at each end with the designation of the terminal block to which it is connected. Individual conductors in each pair of twisted-pair cable shall have distinctly different colors, such as black and white, black and clear. Shield ground common wires connected between drain wire terminals shall be green and shall be tagged "SG".

D. Terminal Blocks.

1. Unless otherwise shown or specified, terminal blocks shall be captive screw with pressure plate, DIN EN 50035 rail 600Vt rating.. Terminal blocks shall be the type specified in the following table, or approved substitution:

Description Type Application Terminal Block Phoenix UK 5 N 120 VAC, Neutral Grounding Terminal Phoenix USLKG 5 Equipment Grounding Block End Clamps Phoenix E/NS 35 N Each Group of Blocks Terminal Marking Phoenix ZB 6 All terminal Blocks as required Terminal Strip Marker Phoenix KLM-A Each Group of Blocks Insertion Strip Phoenix ESL As Required

2. Provide Phoenix Contact UK6.3 fused disconnects with light indicators for 24VDC and 120VAC circuits with fuses as shown on the drawings (www.phoenixcon.com). Provide 20 fuses of each type as spares. 3. All PLC, RTU or remote I/O points shall be terminated at terminal blocks within the respective enclosure. Terminating field wiring directly to I/O modules is not permitted.

E. Terminal Tags, Covers and Markers. Each terminal strip shall have a unique identifying alphanumeric code designation at one end and a plastic marking strip running the entire length with a unique number for each terminal. Assign terminal strip numbers from the number "1" and continuing in ascending cardinal order. The terminal strip designation shall be the letters "TB" followed by the terminal strip number. The strip and terminal point designations shall be machine printed and l/8” high. Terminal blocks carrying 120VAC power circuits shall be provided with a transparent, hinged cover for personnel protection and accessibility.


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F. Wire Routing. Wires shall be routed in slotted plastic wire-ways with snap covers. Wires carrying 120VAC shall be separated from other wires and signal cables, and shall be routed only in ducts shown on the drawings to be for 120 VAC. If the power wiring has to cross the signal wiring, the crossing shall be as close to a right angle. Ducts shown for 24VDC shall be used for all other wires and cables. Wires and cable shall be routed along the shortest route between termination points, excepting routes which would result in routing 120VAC and other wires and cables in the same duct. For intrinsically safe signal wiring refer to ANSI/ISA RP12.6 "Installation of Intrinsically Safe Instrument Systems in Class I Hazardous Locations." Wires and cables shall have sufficient length to allow slack and to avoid any strain or tension in the wire or cable. Wires and cables shall be placed in the ducts in a straight, neat and organized fashion and shall not be kinked, tangled or twisted together.

G. Wire Terminations.

1. Single wire and cable conductors shall be terminated according to the requirements of the terminal device. 2. For captive screw, pressure plate and screw terminals, appropriately sized lugs shall be used. Lugs shall be crimp on type that form a tight connections. All crimping shall be done using a calibrated crimping tool made specifically for the lug type and size being crimped. 3. On shielded cables, the drain wire shall be covered with insulating tubing along its full bare length between the cable jacket and the terminal lug or terminal pressure plate.

H. Single Position Indicating Lights.

1. Single position indicating lights shall be push-to-test LED, 24VDC, NEMA 13, heavy-duty, oil-tight, nominal 1.5 inch diameter. The lens color shall be as designated on drawings. 2. Single position indicating lights shall be Allen Bradley, Square D, or approved substitution.

I. Electro-Mechanical Relays. Control relays shall be UL or CSA approved, and provided with two Form C silver contacts rated at 3 amperes at 28 VDC, and shall be hermetically sealed. Where the drawings show a requirement for more than two contacts for a single control relay, two relays shall be provided with the coils wired in parallel. Coils shall be 24VDC. Relays shall be mounted on sockets with retainers, and shall be wired with drop out voltage spike suppression diodes in parallel with all coils, with the cathode of the diode connected to the positive side of the coil. Electro-mechanical Control Relays shall be IDEC (www.idec.com) type RY2S-LD with indicator light, Potter and Brumfield (www.tycoelectronics.com), or approved substitution.

J. Cabinet Lighting. Each panel shall be provided with an internal fluorescent light. Lights shall operate from 120VAC, and shall be wired to power through a door-mounted switch, which shall be activated by opening the cabinet door, to be located and wired as shown. Cabinet lights shall be Hoffman ALF16D18R, or approved substitution.

K. Circulation Fan. Provide a 120-volt circulation fan with mounting bracket in each panel. Fan shall be 4” capable of 100-cfm.

L. Power Line Surge Protectors. Each panel shall be provided with a 120VAC, 20 Ampere service power line surge protector. The surge protectors shall be heavy duty, multi-stage, and high speed. Response time shall be 5 nanoseconds maximum, and shall allow 340 Volts maximum peak surges to pass through. Protector shall be wired to the cabinet ground bar via a dedicated #8 AWG solid copper wire. The power line surge protectors shall be EDCO Type HSP-121 (www.edcosurge.com), or approved substitution.


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M. PLC/RTU I/O Wiring Requirement. All PLC/RTU I/O logic circuit wiring inside the PLC/RTU panel shall conform to the requirements specified below:

1. Discrete Input Wiring Requirement. Each spare discrete input shall be hardwired to the terminal. 2. Discrete Output Wiring Requirement.

a. No matter what type of PLC/RTU discrete output will be used in the systems, “dry” contact or semiconductor/transistor type output, every discrete output shall have an interposing relay for an isolation of PLC/RTU I/O board from the field side. The interposing relay shall be rated 24VDC coil and 2 amp contact for 120VAC or 24VDC. If transistor type of discrete output board is selected and used for DC circuit, a drop out voltage spike suppression protection circuit shall be paralleled in each coil circuit. Provide a fuse per common group. b. Each spare PLC/RTU output or output relay shall be hardwired to the terminal block.

N. Analog Input and Output Wiring Requirement. Each analog I/O shall have a voltage surge arrester in circuit to protect analog input from the any electronic surge damage. Dehn (www.dehn-usa.com) DIN mounted overvoltage arrester Blitzductor or DEHNconnect series shall be used in each analog circuit, including all spare I/O. Provide a fuse for each analog signal.

O. Panel Ground.

1. Each panel shall be provided with a 1 inch high x 0.25 inch thick solid copper grounding bus bar across the bottom of the panel. The grounding bar shall be mounted on insulated standoffs so that no electrical connection is made between the grounding bar and the cabinet through the mounting. The ground bar shall be drilled and tapped for a .25-20 screws at .5 inch intervals along its entire length. 2. An uninsulated solid copper #8 AWG ground wire shall be attached between the ground bar and the panel enclosure, and between the ground bar and the mounting panel.

P. Power Supply. Each panel shall be provided with 24VDC switching type power supplies connected in parallel via current steering diodes. These power supplies shall operate from 120VAC input power and shall provide direct current output current of its rating amperage at 40C, and shall be adjustable from 24 to 28 VDC by screw driver operated adjustment. Input power regulation shall be .2% from 105 to 130 VAC. Output load regulation shall be .2% maximum from zero to full load. Ripple shall not exceed .5% at full load. The power supplies shall have integral output current limiting and over voltage protection. The power supplies shall have fully enclosing cases. The power supply shall be manufactured by Rockwell 1606 series, or approved substitution.

Q. Condensation Heater. Provide thermostatically operated condensation space heaters, which are sealed and safe to touch.

R. Wiring Duct. Plastic wiring duct shall be slotted type with dust cover, panduit type e or ne, as required.


3.1 TEST REQUIREMENTS

Shop test the panels and correct any defects discovered prior to delivery. These tests shall consist of the following:


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A. Verify that each wiring connection is made properly by checking electrical continuity, ensuring that connections have less than one Ohm resistance end to end, and that no cross continuity exists between separate circuits.

B. Conduct a test of all power circuits and power supply equipment to verify that proper voltages are delivered and all power supply equipment is operating according to the manufacturer's specifications. These tests shall be witnessed by the Engineer. Certify the results in writing to the Owner.

C. Functionally test each electrical device to verify correct operation. Test each input/output point. Inputs shall be exercised at the location in the panel the greatest distance in the circuit from the PLC/RTU chassis and verified through to the PLC/RTU processor. Results shall be demonstrated on a programming terminal. Each output shall be exercised from a programming terminal and verified through to the panel location the greatest distance in the circuit from the PLC/RTU chassis. Analog inputs and outputs shall be tested at 0%, 25%, 50%, 75%, and 100% of range. This test shall be witnessed by the Engineer and certify the results in writing to the Owner. Test the operator interface unit, including simulated alarm conditions.

D. Test Ground Fault Interrupter (GFI) receptacles and circuit breakers for proper operation by methods sanctioned by the receptacle manufacturer.

3.2 PANEL INSTALLATION

A. Shop Testing. Coordinate panel delivery with the construction of the control room and panel locations to minimize field handling.

END OF SECTION


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DATA NETWORKING EQUIPMENT 13417-1

SECTION 13417

DATA NETWORKING EQUIPMENT



This section includes the requirements for the providing data networking equipment as specified herein. All products shall conform to the provisions of this section.

1.2 REQUIRED EQUIPMENT

Networking equipment, including managing and configuration software, shall be supplied and conform to the quantity(s) indicated on the drawings and specified herein.


All networking hardware, software, and accessories provided shall be the product of a manufacturer regularly engaged in manufacturing of this equipment whose products have been in satisfactory service for not less than 3 years.

1.4 NETWORKING EQUIPMENT LAYOUT

Install networking equipment in accordance with manufacturers’ recommendations, allowing to facilitate easy installation, removal and maintenance of each component, and normal operation of the component by operating and maintenance personnel. Data networking equipment layout shall allow space for routing of wiring without kinking or bending around sharp edges, and for free flow of air around and through equipment, which requires ventilation for cooling.

1.5 WARRANTY

Provide an all-inclusive 1-year warranty service for labor and materials following field acceptance test completion.

1.6 MANUALS

The manufacturer shall provide operating manuals for the supplied equipment herein.


Unless otherwise specified, electrical equipment and material provided under this contract shall be listed and labeled for the purpose for which it is used by the Underwriters Laboratories, Inc. (UL). This requirement may be waived only if a UL listing is not available for the type of product and approved by the Engineer.

1.8 SUBMITTALS

A. General. Submit for all items supplied.

B. Product Data. Provide data sheets for equipment and software specified.


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2.1 MANAGED ETHERNET SWITCH

A. The managed Ethernet switches shall be capable of supporting the ring configuration shown in the Drawings and meet the following requirements:

1. Modular chassis consisting of a base switch and expansion modules, supporting up to a maximum of 26 ports. 2. Base switch: Supplied with 4 - 100Base FO ports and 6 – 10/100 copper ports. 3. Compact flash memory slot for storing switch configuration. 4. Operating temperature: -40 to 60 C. 5. Power requirements: 24VDC/48VDC.

B. Software support for the following:

1. Cisco Internet Operating System. 2. Virtual LAN. 3. Quality of Service. 4. Bandwidth Threshold Alarming. 5. STP/RSTP. 6. Resilient Ethernet Protocol. 7. Device Level Ring. 8. MAC ID Port Security. 9. DHCP per port. 10. SNMP Support. 11. IEEE 802.1x Security. 12. IGMP Snooping and Query. 13. EtherChannel. 14. CIP SYNC (IEEE 1588).

C. Suppliers.

1. Rockwell Stratix 8000 Series. 2. Cisco IE 3000 Series. 3. Or approved substitution.

2.2 DSL Module

A. Relocate existing DSL modem from existing Plant 6 Control Panel to the new Control Panel. Coordinate relocated service with Consolidated Service DSL.


Not used.

END OF SECTION


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INSTRUMENT COMMISSIONING 13420-1

SECTION 13420

INSTRUMENT COMMISSIONING



This section includes the requirements for the provision of instrument commissioning, including but limited to inspection, operational testing, adjustment and calibration of each device, subsystem and system and placement of each device and system into service.

1.2 SUBMITTALS

A. Test Plan.

1. At least 60 days before commissioning starts, submit a description of the tests to be conducted. 2. Include list of test equipment, test procedures, checklists and test report formats. 3. At the completion of each commissioning phase, deliver all test reports for that phase to Engineer with statement that phase test requirements have been satisfied. 4. Make shop drawing distribution.

B. Responsibility. Review for acceptance by the Engineer of any plan, report or other commissioning activity will not relieve the contractor of his responsibility to meet the contract requirements.

C. Description. Provide field instrumentation accessories to complete installation of sensors, meters, switches, transmitters and similar devices. Each installation includes:

1. Device. 2. Mounting stand where required. 3. Process leads, connectors, valves, support means and all other devices and material required for a complete installation.


A. Referenced Standards.

1. ANSI C37-90a. 2. API RP550. 3. ASTM 153. 4. ASTM B 62.

B. Factory Testing.

1. Subject each device to a complete functional test. 2. Wet flow calibrate flow meters to within specified accuracy. 3. Submit a certified calibration report for each meter showing results of calibration at a minimum of five points evenly spaced throughout range.


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4. Apply a Surge Withstand Capability test wave: a. As defined in Section 2 of ANSI C37.90a-1974, to each power supply circuit, battery circuit, signal circuit, output circuit and input circuit. b. Application of test wave shall be as described in Section 4 of ANSI C37.90a-1974. c. Submit a certified copy of test showing the no load test waveform, details of test wave generator circuit and description of test conducted.

1.4 SUBMITTALS

A. Product Data.

1. Submit vendor specification information along with a corrected copy of applicable specification form for each scheduled device specified in this section. 2. Submit vendor specification information for each material and unscheduled device specified in this section.


2.1 MATERIALS

A. Devices and systems are specified in other sections of this specification. Reference to "devices" means all devices included in the contract.

B. Any device that fails to meet contract requirements or published performance specifications of the manufacturer must be repaired or replaced as directed by the Engineer at no cost to Owner.

C. Demonstrate that test equipment is fully operational and properly calibrated.

D. The Engineer reserves the right to disapprove test equipment that is improper or functioning improperly.


3.1 OBSERVATION

A. The Engineer reserves the right to witness any test, inspection, calibration, or start-up activity.

B. Notify the Engineer in writing at least 24 hours in advance of any test. All tests executed without notifying the Engineer are invalid and must be repeated.

C. Perform commissioning of each device, subsystem and system under direct supervision of the individual manufacturer's factory-trained representative.

3.2 REPORTS

A. Prepare report showing test procedures, conditions and results of each test. In the test report, give applicable contract requirements, manufacturer's performance specifications, and permissible tolerances at each test point, actual values of test signals and actual values of test results. Provide report bound in a three ring binder.


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B. Check-off List.

1. Maintain a check-off list by loop number indicating tasks remaining to be done to make loop operational. 2. Submit check-off list form at least 60 days before commissioning starts. 3. Submit check-off lists when requested by Engineer. 4. Lists will be requested no more frequently than once a week.

3.3 SCHEDULING GUIDELINES FOR COMMISSIONING PHASES

A. Perform all commissioning in accordance with the instructions on the Contract drawings, these specifications, manufacturer's instruction manuals and the direction of the Engineer.

B. Commission field devices, after installation of field instruments and prior to commissioning the instrument or the control panel.

C. After installation of the instrument or control panel and prior to loop commissioning, commission panel-mounted devices and systems.

D. After commissioning field devices and panel-mounted devices, commission loops.

3.4 REQUIREMENTS

A. Transmitters and Receivers.

1. Remove shipping stops before starting with these procedures. 2. Have manufacturer's instruction manuals available. 3. Install miscellaneous components such as charts, illumination, etc., which have been supplied separately but are integral parts of equipment. 4. Test and exercise each instrument to demonstrate correct operation, first individually, then collectively as a functional network. 5. Check calibration of and recalibrate, where necessary, instruments at a minimum of four points over full operational range and prove instruments to be within specified accuracy. 6. Calibrate instruments individually and, where applicable, as loop (i.e., transmitter, controller and valve). 7. Specified accuracy for loop is defined as root-mean- square-summation (RMS) of individual device specified accuracies. 8. Individual device specified accuracy requirements shall be as specified by contract requirements or by published manufacturer accuracy specifications whenever contract accuracy requirements are not specified. 9. Test each loop by applying simulated analog and/or discrete inputs to first elements of loop (i.e., applying simulated analog and/or discrete sensor signals) and measuring outputs from final elements of loop, (i.e., controllers, alarms, indicators, etc.). 10. Apply continuously variable analog inputs to verify proper operation and setting of discrete devices (i.e., alarms, etc.). 11. Make provisional settings on controllers, alarms, etc., during loop installation tests. 12. Prepare calibration report on each instrument and loop.

B. Integrators, Ratio Relay, etc.

1. Check devices in conformance with manufacturer's recommendations.


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2. Receiver integrators may be calibrated for proper operation and multiplication factor by feeding maximum input signal for a specified period of time using a stopwatch. 3. Ratio signals may be simulated to check proper ratio settings and output.

C. Flow Meters and Level Transmitters.

1. Perform volumetric draw down of fill test for all liquid flow meters and level transmitters. 2. Prepare test report for each meter and level transmitter. 3. If test results conflict with calibration report, recalibrate in accordance with subparagraph A above, and repeat volumetric draw down or fill test. 4. Continue until draw down test results prove calibration to be correct.

D. Level Switches. Perform draw down test for each level switch. Set switch in accordance with specifications or in absence of switch setting in specifications, set in accordance with instructions from Engineer.

E. Controllers.

1. Check control action of each controller. 2. Check calibration of gain, integral and rate adjustments where specified including all modes of operation. 3. For each setting, check output for at least three inputs evenly spaced through input range. 4. Check at least three settings for each adjustment evenly spaced throughout the adjustment range. 5. Run all diagnostic procedures.

F. Interlocks. Ring and check interlocking circuits for conformance to plans and specifications.

G. Start-up of Instruments.

1. Test each control loop under start-up and steady-state operating conditions to verify that proper and stable control is achieved using instruments in each instrument panel and control panel.

a. Test control of final control elements using specified modes of manual and automatic control. b. Demonstrate bumpless transition between control station modes. c. Use signals from transducers, sensors and transmitters. d. Simulated input data signals may be used subject to prior written approval by the Engineer.

2. Set proportional band, reset rate and derivative settings for each controller as recommended by manufacturer. 3. Verify transient stability of each control loop by applying control signal disturbances, monitoring amplitude and decay rate of control parameter oscillations and making necessary controller adjustments to eliminate excessive oscillatory amplitudes and decay rates while retaining control sensitivity. Verify proper suppression of "reset wind-up."

H. Component Calibration Sheet.

1. Calibrate and ring out all devices that are to be interfaced with the distributed control system, including devices purchased and installed under other contracts. 2. Each active instrument element (except simple hand switches, lights, etc.) and each I/O module shall have a Component Calibration Sheet. These sheets shall have the following information, spaces for data entry, and a space for signoff by the contractor.


WATER PLANTS


a. Project name. b. Loop name. c. Component tag number or I/O module number. d. Component code number. e. Manufacturer. f. Module number/serial number. g. Summary of function requirements. h. For indicators and recorders. scale and chart ranges. i. For transmitters/converters. input and output ranges. j. For computing elements. k. I/O modules. required and actual inputs or outputs of 0, 10, 50, and 100 percent of span, rising and falling. l. Space for comments. m. Space for signoff by Contractor.

3. Maintain the Loop Status Reports and Component Calibration Sheets at the job site and make them available to the Engineer at any time.

END OF SECTION


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WATER PLANTS

INSTRUMENTS 13421-1

SECTION 13421

INSTRUMENTS



This section includes the requirements for the provision of field instrumentation, including but not limited to analytical, flow, level, and pressure instruments.


A. All instruments shall be of the quality as specified.

B. All instruments are to be factory-tested to assure proper function and operation. The Contractor shall supply test results and calibration records.

C. Contractor shall be responsible for instrument installations and configurations.

1.3 SUBMITTALS

Provide submittals in accordance with the specifications.

1.4 JOB CONDITIONS

A. Environmental Requirements. The equipment shall operate in ambient temperature 0-130F, relative humidity 0-100%.

B. Project Power. 120VAC, 60 hertz single-phase. Contractor shall provide appropriate isolation and protection. Two-wire type transmitters shall be capable of operation from a 24VDC supply.

C. Standard Signal.

1. Output Signal. Each instrument, which outputs a signal, shall output the standard 4-20 mA signal. The signal shall be constant over a load range of 0 to 600 ohms. 2. Input Signal.

a. Electronic devices, such as controllers, match function devices etc., shall have an input impedance of one Mohm minimum for an input signal of 1 to 5VDC. b. The 1 to 5VDC signal shall be developed by the standard 4 to 20 mA transmitted signal through a precision 250 ohm, one-watt resistor. c. These requirements allow several receiving units to monitor the same transmitting unit without causing any perturbation of the received signal. d. Receiving devices shall not be wired in parallel.


WATER PLANTS

INSTRUMENTS 13421-2


2.1 ANALYTICAL EQUIPMENT FURNISHED

A. Chlorine Residual Analyzer.

1. See Section 11500 for Chlorine Residual Analyzer requirements.

2.2 PRESSURE EQUIPMENT FURNISHED

A. Pressure Switches.

1. Weatherproof NEMA 4X housing. 2. 25- 200 psi range. 3. 316SS pressure port and diaphragm with Viton O-ring. 4. Provide with diaphragm seal. 5. DPDT switch rated 5A at 125/250 VAC. 6. Dwyer Mercoid Series Series DA/DS Bourdon Tube.

B. Pressure Gauges.

1. 316SS case, liquid-filled, provide with diaphragm seal. 2. Wika 233.54 Series.

C. Pressure Transmitters.

1. Foxboro IDP10

2.3 FLOW METER EQUIPMENT RELOCATED

A. 12” magmeter at Water Plant 6 will be provided by the owner and shall be installed in the new flow meter vault. See shop drawings submittal in Appendix A.


3.1 INSTALLATION

A. Install instruments and associated devices. Coordinate exact locations with Engineer as shown on the drawings.

B. Install instruments in various locations in the field and on panels. Coordinate exact locations with Engineer.

C. Coordinate outages and shutdowns with Engineer. Quantity and duration of outages and shutdowns are to be minimized.

D. Starting or stopping of any existing pump; opening any existing breaker, or disconnecting any instrument; shall be approved in advance through the Engineer. All installations shall be in accordance with the Manufacturer's recommendations and instructions.

E. All the necessary mounting accessories shall be provided.


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INSTRUMENTS 13421-3

END OF SECTION


WATER PLANTS

INSTRUMENTS 13421-4

APPENDIX A


WATER PLANTS

INSTRUMENTATION ACCESSORIES 13422-1

SECTION 13422

INSTRUMENTATION ACCESSORIES



This section includes the requirements for the provision of field instrumentation accessories necessary for the complete installation of sensors, meters, switches, transmitters, and similar devices. In particular, each installation shall include the device, mounting stand, where required, and process leads, connectors, valves, support means, and all other devices and material required for a complete installation.


A. Referenced Standards.

1. ANSI/IEEE C37-90-1. 2. API RP550. 3. ANSI/ASTM 153. 4. ANSI/ASTM B 62.

B. Factory Testing.

1. Subject each device to a complete functional test. 2. Provide 3-point calibration certificate (NIST traceable) or perform wet flow calibration of flow meters to within specified accuracy. 3. If NIST traceability not provided, submit a certified calibration report for each meter showing results of calibration at a minimum of five points evenly spaced throughout range. 4. Apply a Surge Withstand Capability test wave:

a. As defined in ANSI/IEEE C37.90-1, to each power supply circuit, battery circuit, signal circuit, output circuit and input circuit. b. Application of test wave shall be as described in Section 4 of ANSI C37.90-1. c. Submit a certified copy of test showing the no load test waveform, details of test wave generator circuit and description of test conducted.

1.3 SUBMITTALS

A. Product Data. Submit vendor specification information along with a corrected copy of applicable specification form for each device specified in this section.


2.1 UNSCHEDULED DEVICES

A. Hand Valves. Provide process valves at all process taps for isolation of instrumentation equipment except where safety would be compromised by their use.

1. General. Valves must provide straight-through passage and tight shutoff to the rating of the valve.


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2. Air Service. a. Provide line size ball valve with stainless steel Swagelok body. b. Acceptable Manufacturers.

1) Whitey (www.swagelok.com). 2) Parker (www.parker.com). 3) Approved substitution.

3. Water service with fluid pressure below 200 psig and fluid temperature below 300 F: a. Provide 3/4-inch ball valve with stainless steel swage lock body, disc, union bonnet, and TFE impregnated non-asbestos packing. b. Acceptable Manufacturers. Crane No. 431 UB (www.cranevalve.com) or approved substitution.

B. Pulsation Dampener.

1. Provide pulsation dampers where gauges are subject to pulsations and/or where indicated. 2. Provide damping by means of self-cleaning pin or piston. 3. Make provisions to vary amount of damping while preventing accidental shutoff.

C. Receiver Gauges.

1. Calibrate scale in process units with tick marks for milliampere input in engineering units. 2. Provide diode to maintain loop continuity in case of meter movement failure. 3. Accuracy shall be as specified for panel meters.

D. Pressure Gauges.

1. Provide 1% ASME Grade A, open front, 304 stainless steel with 100 mm dial, glycerin-filled pressure gauges. 2. Ring Type: 304 stainless steel. 3. Bourdon Tube: 316 stainless steel. 4. Socket: 316 stainless steel. 5. Range Limits: Vac/15,000 psi. 6. Connection Size & Location: 1/2” NPT – lower. 7. Window: Shatterproof glass. 8. Ashcroft Series 1009 or approved substitution.

E. Mounting Brackets.

1. 2-5/8-inch channel section. 2. 316 stainless steel. 3. Acceptable Manufacturers:

a. Unistrut (www.unistrut.com). b. Approved substitution.

F. Nameplate.

1. Provide each device with a nameplate identifying tag number and service as specified on device specification form. 2. Make nameplates of 12-gauge stainless steel. 3. Machine-print each nameplate inscription as shown with letters clearly readable from a distance of four feet directly in front of nameplate.


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4. Attach nameplates using a minimum of two self-tapping stainless steel sheet metal screws or six-inch length of stainless steel link chain. 5. Name list must be approved by the Engineer before nameplate engraving. 6. External Power Supply. Provide an internal or external on-off switch for each instrument requiring power from an external power source.

G. Surge Protection.

1. Provide surge protection on all 4-20 mA inputs to all analog devices. 2. The surge protection device shall protect field instrumentation from impulses up to 500V or 10,000A induced by lighting strikes or heavy electrical equipment. 3. The protection device shall be NEMA 4X and installed in accordance with manufacturer's recommendations.

H. Instrument Stand.

1. Provide a 52-inch high, 2-inch diameter instrument stand for all instruments mounted from the floor. Stand shall be coated with a Zinc Arc Spray Metallizing for corrosion protection. 2. Acceptable Manufacturers. O’Brien Instruments, FP52.

I. Instrument Sunshield.

1. Provide opaque sunshields for all instruments mounted outside. Sunshields shall provide UV protection to all LCD instrument displays. 2. Acceptable Manufacturers. O’Brien Instruments, or approved substitution.


3.1 PREPARATION

A. Coordination. Coordinate equipment delivery with completion of other work to minimize field handling of each device.

B. Verify dimensions in field prior to fabrication.

3.2 INSTALLATION

A. Mount pipe, and connect field devices in accordance with contract drawings, specification and manufacturer's installation instructions.

B. Avoid tubing, piping and conduit interferences.

C. Locate equipment to be accessible for operation, maintenance and replacement.

D. Examine contract drawings and shop drawings for equipment in order to determine best arrangement for work as a whole.

E. Mount field transmitters 40 to 66 inches above floor, work platform, or as sensing line slope requires per manufacturer’s guideline. Coordinate tap location and meter location with Engineer prior to beginning work.


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F. Where specifications and contract drawings do not delineate precise installation procedures, use API RP550 as a guide to installation procedures. Submit sketch for the Owner’s approval prior to installation.

G. Where field devices are shown as yoke mounted on a floor stand, a wall bracket fabricated from two channel sections 1-5/8 inches mounted to a wall or column is considered equal.

H. Make channel section long enough to mount at least two field devices.

I. Use 316 stainless steel for fabrication.

J. Locate instrument-mounting stands within 5 feet of primary element, unless otherwise indicated. Make stands freely accessible.

K. Locate indicating instruments which must be visible for automatic control adjustment or manual operation to be visible from the adjustment or operating point. If plot or piping arrangement precludes this, make other provisions for indication at the adjustment or operation point.

L. Install instrument mounting stands after all conduit and pipe have been installed, except conduit serving devices on stand.

M. Install instrument process piping and tubing from each primary shutoff valve to appropriate gauge, sensor, meter, analyzer, control panel connections, etc.

N. Clean piping, tubing and components thereof prior to installation. This shall include but is not limited to special cleaning procedures for oxygen service when so required.

O. Adjust pulsation dampers to eliminate rapid fluctuations of gauge or switch but to retain sensitivity to pressure changes.

3.3 SUPPORT OF FIELD-MOUNTED INSTRUMENTS

A. Locate field-mounted instruments as shown on drawings or as designated by the Engineer.

B. Secure support pipes, stands or brackets of material with sufficient strength to prevent excess vibration or movement.

C. Locate all transmitters, unless otherwise specified on instrument piping drawings, 40 inches above floor, platform, or as sensing line slope requires per manufacturer’s guidance, in a location to allow convenient access for readability, calibration and maintenance.

END OF SECTION


WATER PLANTS

SYSTEM CONFIGURATION 13430-1

SECTION 13430

SYSTEM CONFIGURATION



This section includes the requirements for the provision of an instrumentation system for monitoring and control of the treatment process as described herein, and as indicated on the drawings.

1.2 SUBMITTALS

Submit IEC 61131 logic diagrams, graphic screen sketches, description of the loop in his/her own words. The diagrams shall include all PLC logic and computer input/outputs.


2.1 GENERAL

A. Hardware components, equipment, and related items for the instrumentation system shall be as indicated on the drawings and in the specifications.

B. The monitoring and control of various functions of this plant comprise of control narratives as described herein, with a description of instruments and related items given in other sections of the specifications and shown on the drawings. The following description is brief for the purpose of understanding the control philosophy only. Important loops have been described; for the remaining loops, refer to plans and other sections of the specifications.

C. Utilize the following “systems integrator” for software programming:

Prescott Control Solutions 4822 Gypsy Forest Drive Humble, TX 77346 Attn: Jeff Prescott, Project Manager 281-808-1642 Email: [email protected]

2.2 HUMAN MACHINE INTERFACE (HMI)

A. When applicable, upgrade the existing HMI.

B. Provide proper installation and licensing of the various software packages as defined in the specifications. Demonstrate the redundancy features of the system.

C. Graphical User Interface. When applicable, follow the existing guidelines when upgrading the screens.

1. Present process information on a set of project specific graphical screens that accurately represent the actual process and facilities. 2. Include navigation aids that logically link screens.


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3. Use animation in the form of color-codes, motion, variable fill, and alphanumerical data to alert and inform the operator.

D. Process Monitoring. When applicable, follow the existing guidelines when developing the screens for process monitoring.

1. Scan, collect and display discrete and analog variables on process graphic displays. 2. Present and organize data on screens to facilitate facility monitoring and control. 3. Organize screens to support operations tasks.

E. Process Control. When applicable, follow the existing guidelines when developing the screens for process control.

1. Provide for and accept operator entries and commands on the process graphic displays. 2. Integrate operator entry functions into process graphic displays to ease monitoring and control.

F. Alarm Management and Operator Paging. When applicable, follow the existing guidelines when developing the screens for alarm management and operator paging.

1. Annunciate abnormal conditions and log alarms status (occurrence, acknowledgement, clearance, and reset) changes, as well as designated events. 2. Annunciate alarms on the graphic displays and maintain a summary of active (not cleared, annunciated and reset) alarms. 3. Use color codes to highlight alarm status on graphic and summary displays. 4. Log on the alarm/status printer, alarm and event status changes as they occur.

G. Reporting. When applicable, transfer the existing reports to the new system.

1. Modify the database links to match the naming conventions created for the project. 2. Follow the existing guidelines for the format of the reports. 3. Verify the proper operation and accuracy of the data on the reports. 4. Provide the operator with the ability to activate and modify the reports from the process graphic screens.

H. Historical Data Collection. When applicable, follow the existing data collection requirements when developing the storage and update frequencies of the historical data.

1. Create the necessary database tables to collect and maintain the historical data. 2. Verify the proper collection of the data. 3. Demonstrate the access to the data from periodic reports and/or process graphics.

2.3 PROGRAMMABLE LOGIC CONTROLLERS (PLC)

Program the PLCs in a systematic and organized manner. The programming code shall be fully documented, and provide the same functionality that currently exists.

2.4 REMOTE TERMINAL UNITS (RTU)

Program the RTUs in a systematic and organized manner. The programming code shall be fully documented, and provide the same functionality that currently exists.


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None

END OF SECTION


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WATER PLANTS

INPUT/OUTPUT LIST 13440-1

SECTION 13440

INPUT/OUTPUT LIST



This section includes the requirements for the provision of the necessary hardware to monitor and control the input/output subsystem. The preliminary input/output lists are attached at the end of this section.

1.2 SUBMITTALS

Submit an input/output list, in Microsoft Office Excel format, that includes PLC panel number, card and point location, configuration information, point description, point function and tag name.


2.1 GENERAL

The input/output list shall contain all items to be configuration items of the point and shall be capable of being imported and exported into the system via an Excel spreadsheet.


3.1 INPUT/OUTPUT LISTS

Refer to the attached list for input/output listing for each PLC system point.

END OF SECTION


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INPUT/OUTPUT LIST 13440-2


PLC POINT LISTSURFACE WATER SYSTEM IMPROVEMENTS - WATER PLANTS

STATION POINT DESCRIPTION INSTRUMENT LOCATION TYPE

PROPOSED CP

TBD OVERHEAD DOOR ALARM WP6 DI

PROPOSED CP

TBD OVERHEAD DOOR ALARM WP6 DI

PROPOSED CP

TBD PUMP HOUSE DOOR ALARM WP6 DI

PROPOSED CP

TBDPHOSPHOROUS ROOM DOOR ALARM

WP6 DI

PROPOSED CP

TBDCHLORINE ROOM DOOR ALARM

WP6 DI

PROPOSED CP

TBD SECURITY GATE ALARM WP6 DI

PROPOSED CP

TBD MOTION SENSOR ALARM WP6 DI

PROPOSED CP

TBD MOTION SENSOR ALARM WP6 DI

PROPOSED CP

TBD CHLORINE LEAK ALARM WP6 DI

PROPOSED CP

TBD GENERATOR NOT IN AUTO WP6 DI

PROPOSED CP

TBD GENERATOR FAIL TO START WP6 DI

PROPOSED CP

TBD GENERATOR RUN WP6 DI

PROPOSED CP

TBD GENERATOR LOW COOLANT WP6 DI

PROPOSED CP

TBD GENERATOR LOW OIL WP6 DI

PROPOSED CP

TBD GENERATOR OVERCRANK WP6 DI

PROPOSED CP

TBD BP-1 RUN WP6 DO

PROPOSED CP

TBD BP-2 RUN WP6 DO

PROPOSED CP

TBD BP-3 RUN WP6 DO

PROPOSED CP

TBD WELL PUMP RUN WP6 DO

PROPOSED CP

TBD BP-1 HOA STATUS WP6 DI

PROPOSED CP


PROPOSED CP


PROPOSED CP

TBD WELL MOTOR HOA STATUS WP6 DI

PROPOSED CP

TBDEXISTING GROUND STORAGE TANK LEVEL LIT-01

WP6 AI

PROPOSED CP

TBDEXISTING GROUND STORAGE TANK LEVEL LIT-02

WP6 AI

-10292-003 13440-2 Input/Output List

PROPOSED CP

TBDRELOCATED SYSTEM PRESSURE PIT-01

WP6 AI

PROPOSED CP

TBDEXISTING HYDROSTATIC TANK LEVEL LIT-03

WP6 AI

PROPOSED CP

TBDPHOSPHATE TANK LEVEL LIT-04

WP6 AI

PROPOSED CP

TBD CHLORINE DETECTOR AIT-01 WP6 AI

PROPOSED CP

TBD CHLORINE DETECTOR AIT-02 WP6 AI

PROPOSED CP

TBD WELL FLOWMETER AIT-01 WP6 AI

PROPOSED CP

TBD CHLORINE SCALE WIT-01 WP6 AI

PROPOSED CP

TBD CHLORINE SCALE WIT-02 WP6 AI

PROPOSED CP

TBD PLANT FLOWMETER FIT-02 WP6 AI

PROPOSED CP

TBDCHLORINE FLOW RATE AIT-03

WP6 AI

PROPOSED CP

TBD CHLORINE FLOW SETPOINT WP6 AO

EXISTING CP TBD OVERHEAD DOOR ALARM WP14 DI


EXISTING CP TBD PUMP HOUSE DOOR ALARM WP14 DI

EXISTING CP TBDPHOSPHOROUS ROOM DOOR ALARM

WP14 DI

EXISTING CP TBDCHLORINE ROOM DOOR ALARM

WP14 DI

EXISTING CP TBD SECURITY GATE ALARM WP14 DI

EXISTING CP TBD MOTION SENSOR ALARM WP14 DI


EXISTING CP TBD CHLORINE LEAK ALARM WP14 DI

EXISTING CP TBD GENERATOR NOT IN AUTO WP14 DI

EXISTING CP TBD GENERATOR FAIL TO START WP14 DI

EXISTING CP TBD GENERATOR RUN WP14 DI

EXISTING CP TBD GENERATOR LOW COOLANT WP14 DI

EXISTING CP TBD GENERATOR LOW OIL WP14 DI

EXISTING CP TBD GENERATOR OVERCRANK WP14 DI

EXISTING CP TBD BP-1 RUN WP14 DO




EXISTING CP TBD WELL PUMP RUN WP14 DO

EXISTING CP TBD BP-1 HOA STATUS WP14 DI



EXISTING CP TBD WELL MOTOR HOA STATUS WP14 DI

EXISTING CP TBDEXISTING GROUND STORAGE TANK LEVEL LIT-01

WP14 AI

EXISTING CP TBDRELOCATED SYSTEM PRESSURE PIT-01

WP14 AI

EXISTING CP TBDEXISTING HYDROSTATIC TANK LEVEL LIT-03

WP14 AI

EXISTING CP TBDPHOSPHATE TANK LEVEL LIT-04

WP14 AI

EXISTING CP TBD CHLORINE DETECTOR AIT-01 WP14 AI


EXISTING CP TBD WELL FLOWMETER AIT-01 WP14 AI

EXISTING CP TBD CHLORINE SCALE WIT-01 WP14 AI


EXISTING CP TBDCHLORINE FLOW RATE AIT-03

WP14 AI





WP15 DI


WP15 DI





















WP15 AI


WP15 AI


WP15 AI


WP15 AI







WP15 AI





WP20 DI


WP20 DI





















WP20 AI


WP20 AI


WP20 AI


WP20 AI







WP20 AI






WP21 DI


WP21 DI




















WP21 AI


WP21 AI


WP21 AI


WP21 AI








WP21 AI





WP22 DI


WP22 DI




















WP22 AI


WP22 AI



WP22 AI


WP22 AI







WP22 AI





WATER PLANTS

LIGHTING CONTROLS 13815-1

SECTION 13815

LIGHTING CONTROLS



This section includes the requirements for the provision of lighting controls, including lighting contactors, photocells and timers.

1.2 LISTING

All devices shall be UL listed, offer a 5-year warranty and meet all state and local applicable code requirements.

1.3 SUBMITTALS

A. Manufacturer shall substantiate conformance to this specification by supplying the necessary documents, performance data and wiring diagrams. Deviations from the requirements of this specification shall be clearly indicated in the submittal.

B. Provide product data on dimmers, lighting contactors, timers, occupancy sensors, photocells, wiring devices and plates.


2.1 GENERAL

Lighting controls, including time switches and photocells specified in this section.

2.2 SITE AND EXTERIOR LIGHTING CONTROL

A. Lighting Control Panel.

1. Provide a UL-listed lighting control panel with one or more factory-installed digital timers, HAND/OFF/AUTO(H/O/A) control circuits, and lighting contactors as indicated on the drawings and specified herein. 2. Provide a sufficient quantity of lighting contactors, each with an adequate number of poles to switch connected lighting fixtures. Provide lighting contactors rated for 30 amps, unless noted otherwise.

2.3 LIGHTING CONTACTORS

A. Contactor.

1. Configuration. Provide electrically-held magnetic lighting contactor designed to withstand the large initial inrush current of tungsten and ballast lamp loads as well as non-motor (resistive) loads without contact welding. 2. Coil. Provide contactor coil suitable for continuous operation at 120VAC, 60 hertz. Provide coil suitable for continuous operation at other voltages as indicated on the drawings. Coil shall be


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of molded, encapsulated construction. Permanently mark and/or color code the coil with voltage, frequency and part number. 3. Contacts.

a. Type. Totally enclosed, double break, silver-cadmium oxide or similar material contacts to minimize sticking or welding. Contact inspection and replacement shall be possible without disturbing line or load wiring. Contacts shall have clearly visible normally open (N.O.) and normally closed (N.C.) contact status indicators. b. Rating. 30 amperes for ballasted lighting loads.

4. Auxiliary Contacts. Provide each lighting contactor with the number and type of auxiliary contacts to perform the required functions, plus two spare auxiliary contacts, one normally open and one normally closed. 5. Wiring. The contactors shall have straight-through wiring, with all terminals clearly marked. 6. Line and Load Terminals. Provide captive screws for 30 amp contactors. Terminals above 30 amperes shall be back-out saddle clamp design.

B. Enclosure.

1. Type. a. Indoor. NEMA 1.

2. Finish. a. Exterior. Electrostatically applied enamel powder-coat. ANSI 61 gray. b. Interior. Non-gloss (flat) white.

3. Enclosure shall have extra space to include time clock.

C. Controls.

1. Provide H/O/A control circuit as indicated on drawings. 2. Nameplates. Provide engraved nameplate in accordance with Section 13421, Instruments.

D. Manufacturers. General Electric.

E. Photocontrol and Time Clocks. Provide photocontrol and time clocks in accordance with Section 16145.


3.1 COORDINATION

Verify that the occupancy sensors are compatible with the specified ceiling systems as indicated on the architectural drawings. Advise the Engineer of any discrepancies before placing the device order.

3.2 INSTALLATION

A. Devices must be completely wired and installed. Lighting fixtures and lighting controls must be operating properly at final completion.

B. Provide hangers and support members for devices as required for proper installation. Provide appurtenances which include stud supports, stems, mounting brackets, frames and plaster rings.


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3.3 SITE AND EXTERIOR LIGHTING CONTROL

A. Connect exterior lighting fixtures to lighting contactors provided.

1. Fixtures intended to be switched together shall be connected to poles on the same contactor. 2. Circuits and lighting contactors shall be segregated by voltage (i.e.: only 120 volt circuits on one contactor, only 277 volt circuits on another contactor, etc.).

B. Mount photocell at highest elevation on roof, facing north. Connect photocell to lighting control circuit(s). Adjust Photocell Turn On to appropriate light level (0.75 to 2.5 foot-candles) as directed by Owner.

C. Contractor shall program digital timer for control of fixtures as directed by Owner.

D. Contractor shall verify circuit and contactor ratings for circuits supplying 480VAC fixtures.

E. Conductors for 30 amp, 480VAC site lighting circuits: Use number 8 AWG stranded copper with THHN insulation.

3.4 TESTING

The Contractor shall demonstrate to the Owner the proper operation of all systems and equipment specified in this section. The Contractor shall adjust, repair or replace as necessary all components that do not perform as specified, until able to demonstrate proper operation of equipment in normal, automatic, manual, emergency, power-loss, and power-restored modes of operation, as applicable.

3.5 TRAINING

The Contractor shall provide, at the Owner’s facility, the training necessary to familiarize the Owner’s personnel with the operation, use, adjustment, and problem-solving diagnosis (troubleshooting) of the site lighting control system.

END OF SECTION


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BASIC MECHANICAL REQUIREMENTS 15010-1

SECTION 15010

BASIC MECHANICAL REQUIREMENTS

PART 1 - GENERAL


A. The Work under Division 15 shall be in accordance with the applicable Basic Mechanical Requirements and as specified in each individual Specification Section, in addition to Division 1 - General Requirements.

B. Scope of Work

1. The Work under this Section includes, but is not limited to, furnishing, installing and providing all equipment and services necessary for completion of all Mechanical systems fully serviceable and operational.

2. The Mechanical Work includes, but is not limited to, the following major items and all Work listed in Division 15:

Process and HVAC Mechanical Systems:

a. HVAC Systems

b. Miscellaneous Facilities

c. Station Heating System - Steam Boiler

d. Pumping Facilities

e. Plumbing

f. Ventilation, including emergency area air purge

g. Environmental Control

h. Gas Service (Natural Gas/Propane Gas)

i. Piping Systems

3. Definitions:

a. Piping: Includes, in addition to pipe, all fittings, valves, hangers, and other supports and accessories related to such piping.

b. Ductwork: Includes, in addition to ducts, all fittings, transitions, dampers, hangers and other supports and accessories related to such ductwork.

c. Concealed: Means hidden from sight in chases, furred spaces, shafts, suspended ceilings, embedded in construction, located in crawl spaces or buried.

d. Exposed: Means not installed underground or "concealed" as defined above.

e. Invert Elevations: Means the elevation of the inside bottom of pipe or duct.

f. Mechanical Work: Is all of the work in Division 15.

g. Low Pressure: To mean - 125 psig working pressure (including pump head) or less.

h. High Pressure: To mean - 126 psig working pressure (including pump head) or greater.


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i. Furnish(ed): Purchase and deliver to the project site complete with every necessary appurtenance, and support, all as part of the mechanical work.

j. Install(ed): Unload at the delivery point at the site and perform every operation necessary to establish secure mounting and correct operation at the proper location in the project, all as part of the work.

k. Provide(d), Furnish and Install: All items of equipment and accessories related to the equipment complete and ready for operation.

l. Coating: An internal and/or external paint system, coal tar enamel system or extruded plastic system applied to surface areas of ferrous metals for corrosion protection.

m. Contract Documents: The Contract, the Drawings, and the Specifications.

n. Contractor: One who contracts or is party to a contract.

o. Design Pressure: Maximum coincident pressure in psig. The design pressure shall not be less than the pressure at the most severe condition of coincident internal or external pressure and temperature (minimum or maximum) expected during service, except as provided in ANSI 302.2.9 and ANSI 302.2.9. The most severe condition is the which results in the greatest acquired component thickness and the highest component rating.

p. Dustight: Absence of dust exfiltration and infiltration at joints and connections, and between components when system is operating at maximum design condition.

q. Erect: To install.

r. Equipment: Major machinery, devices, apparatus, or vessels (as contrasted to appurtenances).

s. Field Painting: Painting performed in the field as opposed to the internal pipe, fitting and vessel coatings applied by manufacturers or custom coating applicators.

t. Gastight: Absence of gas or air exfiltration and infiltration at joints and connections, and between components when system is operating at maximum design condition.

u. Pitch: Slope.

v. psia: Pounds per square inch absolute.

w. psig: Pounds per square inch gage.

x. Product: As defined in the conditions of the Contract.

y. Watertight: Absence of water exfiltration and infiltration at joints and connections, and between components when system is system is operation at maximum design condition.

z. Working Pressure: Operating pressure in psig.

C. General

1. All items of Work and systems shall be furnished and installed ready for satisfactory operation and service and all required apparatus and service shall be provided even though not specifically mentioned herein.


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2. The Contract Specifications and Contract Drawing Equipment Schedules list the equipment manufacturers selected for the basis of the Specifications and for the various individual equipment layouts on the Contract Drawings. Substitutions may only be made in accordance with Section 01600.

3. The Drawings showing the layout, arrangements, sizes and principal connections to the equipment and apparatus are based on one particular type of equipment of an acceptable manufacturer.

4. If equipment, other than the one particular type of equipment shown on the layout Drawings is used, it is the Contractor's sole responsibility to make all necessary modifications to related piping, electrical and utility connections, apparatus and miscellaneous items to provide complete Mechanical Work, ready for satisfactory operation required under these Specifications.

5. The cost of making all the modifications shall be borne by the Contractor without extra cost to the Owner.

6. In using such equipment, it is imperative that the equipment must fit the space and the access allotted, with the final layout to be approved by the Owner.

7. Follow the Drawings as closely as actual building construction permits.

8. The Drawings show the principal engineering design elements of the mechanical installation. They are not intended as detailed construction installation Drawings for the Mechanical Work but as a complement to the Specifications to clarify the principal features of the mechanical systems.

It is the intent of this Section that all equipment and devices, including electrical power and controls wiring be furnished and installed under this and other Sections, be properly connected and interconnected with other equipment so as to render the installation complete for successful operation, regardless of whether all the connections and interconnections are specifically mentioned in the Contract Specifications or shown on the Contract Drawings.

9. Check the layout of the Work of this Division, as indicated on the Drawings. Determine exact locations by the dimensions of the equipment approved. Obtain written approval from the Commissioner for any revised layout before equipment or material involved is installed. Consult the Architectural and Structural Drawings for all dimensions, locations of partitions, locations and sizes of structural supports, foundations, swings of door, and other detail information required for a correct installation of this Work.

10. Examine all other Divisions of the Contract Documents for Work related to the Work of this Division. Cooperate to provide continuity of Work, to eliminate duplications, and to provide Mechanical Work in support of such related Work. Furnish to other trades and on schedule all information required for the execution of Mechanical Work.

11. Any additional Work accrued such as cutting, drilling, patching, excavating, moving or another trade's Work, or similar, because of delay in Mechanical Work or information are a part of this Division and shall be borne without increase in Contract Price.

12. Install and connect appliances and equipment with best engineering practice and in accord with the manufacturer's instructions and recommendations. Provide all accessory valves, ductwork, piping, connections, and all similar material recommended by the manufacturer, or required for proper operation and maintenance, complete without additional costs.


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13. Perform any necessary excavation and backfilling to complete the Work of this Division in accordance with excavation and backfill provisions for the applicable Division of this Specification.

14. Provide all necessary rigging, scaffolding, tools, tackle, labor and other materials or equipment which may be necessary for the completion of the Work.

15. Furnish and install motor on proper frame designed by the driven equipment manufacturer. Coordinate with Division 16 - Electrical for power supplies, wiring and other requirements.

16. The Contractor is responsible for providing all electrical Work for all systems as specified or as required or as shown on the Drawings for a complete fully integrated operating system.

D. For equipment specified without factory wired equipped disconnect switches, manual/automatic starter equipment and accessories, Contractor shall also be responsible for providing wiring, disconnect switches, manual/automatic starter equipment and accessories as shown on the drawings or as specified or as required for a complete fully integrated operating systems, all in accordance with applicable Specification, Division 16 – Electrical.

E. It shall be the Contractor's responsibility to obtain equipment data from the various equipment supplier and to prepare diagrams incorporating equipment data as necessary and to coordinate all electrical requirements.

1.2 RELATED WORK SPECIFIED IN OTHER DIVISIONS

A. Openings: Walls, floor ceiling and roof opening specifically shown and identified on the Architectural and Structural Drawings will be provided under other Divisions. Openings not so identified that are required for Mechanical Work, or changes to such openings are part of the Work of this Mechanical Division.

B. Curbs, Drains and Sleeves: Roof curbs, drains, and roof sleeves provided under this Division shall be incorporated into the finished roofing and made watertight under another Division.

C. Equipment Bases: Concrete equipment bases, mounting slabs, and housekeeping pads specifically shown and identified on the Architectural and Structural Drawings shall be provided under other Divisions. Under this Division cooperate and furnish dimensions, sleeves, inserts, hold-down bolts, and templates for their installation. Supervise their installation. Those bases, not so identified and indicated on the Mechanical Drawings, shall be provided under this Division.

D. Painting: Painting of all exposed-to-view pipes, ducts, hangers, supports, and equipment, shall be performed under another Division. Under this Division, all manufactured equipment shall be furnished in factory-finished baked enamel, unless otherwise specified.


A. General:

1. Conform with the Occupational Safety and Health Standards of the U.S. Department of Labor and all applicable ordinances, laws, regulation, and/or codes of the Local Authorities, the City or Municipality, the State, Federal, the National Fire Protection Association, or any other governmental bodies having jurisdiction.

2. Install mechanical work to the satisfaction of the inspecting authority having jurisdiction.


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3. Notify the Owner or his authorized representative in writing of any instances in the Specifications or on the Drawings that are in conflict with any of the aforementioned authorities; required changes to be adjusted before the Contract is awarded. If the Contractor performs any work contrary to such laws, rules, or regulations without notice, he shall bear all cost arising therefrom.

4. Deviations from the Drawings and/or Specifications required for conformance with the applicable codes and/or laws are to be corrected immediately but not until such deviations have been brought to the attention of the Owner or his authorized representative.

5. Applicable codes and/or laws to govern the minimum requirements only; where the Drawings and/or Specifications call for materials, vents, piping, sizes, etc., in excess of the code requirements, the Drawings and Specifications shall govern.

B. Reference Standards: Codes related to mechanical work include but are not limited to

ASME - American Society of Mechanical Engineers

Order Department:

United Engineering Center

345 East 47th Street

New York, NY 10017

ASME - Boiler and Pressure Vessel Code

ANSI- American National Standard Society

ANSI B16.5 - Steel Pipe Flanges, Flanged Valves and Fittings

ANSI B16.9 - Steel Butt Welding Fittings

ANSI B16.10 - Face-to-Face and End-to-End Dimensions of Ferrous Valves

ANSI B16.11 - Forged Steel Fittings, Socket-Welding and Threaded

ANSI B16.25 - Buttwelding Ends

ANSI B31.3 - Chemical Plant and Petroleum Refinery Piping

ASTM - American Society for Testing and Materials

1916 Race Street

Philadelphia, PA 19103

A53- Specification for Pipe

A105- Specification for Forgings

A181- Specification for Rolled Steel Pipe Flanges, and Valves and Parts for General Service

A216- Specification for Carbon Steel Castings

A234- Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel

A307- Specification for Carbon Steel Fasteners


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B61- Steam or Valve Bronze Castings General Service

AWWA- American Water Works Association

6666 W. Quincy Ave.

Denver, CO 80235

EPA Environmental Protection Agency

401 M Street, S.W.

Washington, DC 20460

NFPA- National Fire Protection Association

470 Atlantic Avenue

Boston, MA 02210

NFPA 70- National Electrical Code

NFPA 30- Flammable & Combustible Liquids Code

NFPA 101- Life Safety Code

OSHA- Occupational Safety and Health Administration

(U.S. Dept of Labor)

Government Printing Office,

Washington, DC 20420

C. Installer Qualifications:

All mechanical construction to be by Contractors and Sub-Contractors who have previously installed similar work at major installations.

Contractors and Sub-Contractors involved in the mechanical portion of the work to have a minimum of five years of experience in the type of work they are to participate in.

D. All materials furnished shall be new and shall comply with all applicable standards listed below.

E. All materials or Work found to be defective or not in strict conformity with the Contract Documents, or defaced or injured through any cause, shall be rejected and shall be removed by Contractor and satisfactory material and Work substituted without delay.

F. Contractor shall protect its Work by keeping all piping, equipment, etc., capped or plugged, drained, or otherwise protected from injury by freezing, water damage, or stoppage from material, concrete, sand, or dirt and shall repair any such injury without additional charge to the Owner. Injury shall be interpreted to include scratches, discoloring and denting.

G. The Contractor will be held responsible for any damage caused by it to other contractors' Work.

H. Submit shop drawings and product data for all equipment as specified or scheduled. Update all drawings to "as-built" status on mylar sheets and submit to Owner.

1.4 REFERENCES

Refer to General Conditions, Standard Specifications and as specified in each individual Section.


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1.5 SUBMITTALS

A. Submit under provisions of Section 01330 and individual Sections with additional provision of this Section.

B. General: Within 30 calendar days after date of Contract Agreement, submit to the Engineer a typewritten list of all items of equipment and material proposed for installation on this Contract.

Provide the Specification page number, manufacturer's name, model number, size non-standard accessories specified or required, and any other information required to identify each item.

1. Within 30 days after the Contractor has been given notice of approval of manufacturers, submit shop drawings of equipment and material proposed for this installation.

2. If substitutions have been offered in lieu of specified materials and/or equipment they shall be in accordance with Section 01600.

C. Shop Drawings:

Submit shop drawings for all Work to be done under each of the Mechanical Sections and for all items and assemblies which are to be specifically fabricated for this Contract.

D. Coordination and Fabrication Drawings:

Prepare layout drawings of all system assemblies of this Contract including room layout with equipment and piping, ductwork installations, special purpose systems, and control systems. Include completely dimensioned plans drawn to scale. Show elevations and sections indicating locations of all equipment, piping, ductwork, drains, controls, and other items with reference to columns, walls, slabs, beams, and to components of other systems and work of other trades. Floor plans shall be drawn at not less than 1/4" scale. Tracing of Construction Drawings is not acceptable.

1. Indicate the proposed locations of piping, ductwork, equipment, and materials. Include the following:

a. Clearances for installing and maintaining insulation.

b. Clearances for servicing and maintaining equipment, including tube removal, filter removal, and space for equipment disassembly required for periodic maintenance.

c. Equipment connections and support details.

d. Exterior wall and foundation penetrations.

e. Fire-rated wall and floor penetrations.

f. Sizes and location of required concrete pads and bases.

g. Valve stem movement.

2. Indicate scheduling, sequencing, movement, and positioning of large equipment into the building during construction.

3. Prepare floor plans, elevations, and details to indicate penetrations in floors, walls, and ceilings and their relationship to other penetrations and installations.

4. Prepare reflected ceiling plans to coordinate and integrate installations, air outlets and inlets, light fixtures, communication systems components, sprinklers, and other ceiling-mounted items.


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E. Catalog Cuts:

Submit manufacturer's data sheets and pictures of all standard manufactured items proposed for installation in this Contract. Clearly identify each item proposed, together with all required accessories and fittings, with tag numbers and Specification page and line numbers. Include graphs, curves, or charts, as applicable, with the specified operating point clearly marked.

F. Installation and bolt Setting Diagrams:

Submit complete installation instructions and bolt setting information for items of equipment furnished under Division 15 such as pumps, fans, compressors, tanks, etc.

G. Wiring Diagrams:

Provide specific wiring diagrams and instructions for all equipment, controls or devices which are furnished under Division 15 & 13 and are to be wired & connected.

The diagrams and instructions shall not be of a general or typical nature, but shall be applicable to this Contract.

H. The Contractor shall be responsible for all power and control wiring for the HVAC controls and instrumentation systems for all HVAC systems (including those having interlocked or inter-related components), including the main HVAC systems, related systems, even where wiring is not indicated on electrical drawings.

Power feeders shown on Electrical contract drawings will be provided under Division 16.

It shall be the HVAC Contractor's responsibility to obtain equipment power and control wiring data from the various equipment suppliers and to prepare combined control wiring diagrams incorporating equipment data as necessary and to coordinate all wiring requirements with the electrical subcontractor.

I. Samples:

Where a Contractor proposes a manufacturer, material, or method differing from that specified, the Commissioner may require samples illustrative of the manufacturer, material or method. Submit such samples as part of the shop drawing requirements, and shall include samples of insulation, special finishes, etc.

J. Submittals shall be made in accordance with Subsection 1.3 "Submittal Requirements" and the provisions of Section 01330 and as otherwise required in the Contract Documents.

In submitting shop drawings, illustrations and descriptive material for approval of the Engineer, Contractor must clearly mark each shop drawing, catalog cut, pamphlet or specification sheet as follows, for purposes of identification and record:

Date: (as submitted)

Contract Title:

Location of Project:

Branch of Work: (Mechanical Work)

Specification Paragraph & Page:

Submitted by: (Contractor Name)

Contract No.:


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K. Product Data:

1. General:

Submit manufacturer's specifications, recommendations and installation instructions for mechanical work products required by Division 15: Mechanical. Include manufacturer's published data or certified laboratory test data indicating that each work product meets the specified requirements.

2. Data Included:

Product data to include the following as applicable:

a. Product name and model or catalog designation, and manufacturer' name.

b. Physical description, dimensions and weights.

c. Products properties, characteristics, capabilities and limitations.

d. Data for coordination with other project work.

e. Clear spaces required for handling, installing, operating and maintaining products.

f. Required installation clearances and tolerances, and the location and size of openings or sleeves necessary for installation.

g. Applicable reference standard designations.

h. Product specifications, including protective coatings.

i. Methods and details for anchorage to supporting construction.

j. Data which affects design and construction of supporting structure, including maximum reactions imposed on supporting structures at each connection or bearing point.

3. Certifications: When required, product data shall be certified by product manufacturer. Meet requirements of Paragraph - Certified Submittals of the Article.

L. Record Documents:

1. Prepare record documents in accordance with the requirements of Contract Documents.

In addition to the requirements specified in Contract Documents, indicate the following installed conditions:

a. Ductwork mains and branches, size and location, for both exterior and interior; locations of dampers and other control devices; filters, boxes, and terminal units requiring periodic maintenance or repair.

b. Mains and branches of piping systems, with valves and control devices located and numbered, concealed unions located, and with items requiring maintenance located (i.e., traps, strainers, expansion compensators, tanks, etc.). Valve location diagrams, complete with valve tag chart. Refer to Division 15 Section "Mechanical Identification." Indicate actual inverts and horizontal locations of underground piping.

c. Equipment locations (exposed and concealed), dimensioned from prominent building lines.

d. Approved substitutions, Contract Modifications, and actual equipment and materials installed.


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e. Contract Modifications, actual equipment and materials installed.

M. Inspection and Test Reports:

1. General: Submit inspection and test reports for mechanical work required by Division 15: Mechanical.

2. Definition: Inspection and test reports shall be documented statements of methods, procedures, results and evaluations prepared by Contractor, and installer, manufacturer or supplier, or an Independent Testing laboratory employed by any of these parties to indicate properties, characteristics and capabilities of a product or portion of the work.

3. Presentation: Inspection and test reports shall identify products or work by identification designations indicated in the Contract Documents.

4. Data Included: Inspection test reports shall identify products or work by identification designations indicated in the Contract Documents.

a. Identification of product or work area represented by inspection or test.

b. Methods, procedures and results of inspections and tests, including observations of unusual conditions.

c. Evaluation of results, and acceptability and use limitations.

5. Certification: Inspection and test reports shall be certified by organization who performed inspections, tests and evaluations. Meet requirements of Paragraph: Certified Submittals of this Article.

N. Compliance Certificates:

1. General: Submit compliance certificates for mechanical work as required by Contract Documents.

2. Certification: Compliance certificates shall be certified by issuing organization. Meet requirements of Paragraph: Certified Submittals of this Article.

3. Certificates Required: Submit compliance certificates for the following, in addition to compliance certificates required by other sections of Division 15: Mechanical.

a. Products not of the manufacturer's standard design, modified to suit these requirements.

b. Equipment bearing UL Listing Mark.

O. Certified Submittals: Submittals for mechanical work required are to be certified and shall meet the certified submittal requirements.

1.6 PRODUCT SUBSTITUTIONS

Product substitutions shall be in accordance with Section 01600 - Materials and Equipment.

1.7 POWER AND CONTROL WIRING

A. All factory furnished equipment controls and power wiring plus supplementary field interconnecting power and control wiring for external devices associated with HVAC, chemical applications and other equipment provided under Division 15 shall be furnished, installed, and wired in accordance with the applicable Specification Sections and/or Division 15 including such Work.

1. Under Division 15, provide installation instructions, locating dimensions, and wiring diagrams for the other trades.

2. Supervise the installation, start-up, and testing of the equipment.


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B. All wiring associated with Division 15 & 13 shall comply with all applicable requirements of those divisions and Divisions 15, 16, and 13 requirements.

C. All wiring shown on the drawings will be furnished and installed by the Contractor in accordance with Division 16 of the Specifications.

Except where shown on Electrical Plans in the E-series drawings, all conduits and wiring required for equipment furnished under Division 15 shall be furnished and installed under Division 15.

Wiring shown on Electrical Plans in the E-series drawings shall be furnished and installed under Division 16.

1.8 OPERATING AND MAINTENANCE MANUALS

A. Submittals of operation and maintenance manuals shall be in accordance with Section 01330 – Submittal Procedures, Section 01770 - Closeout Procedures and additional provisions of this Section.

B. Prepare and deliver to the Commissioner, seven (7) complete sets of operating and maintenance manuals for all equipment furnished.

Provide all information pertinent to the equipment for preventive maintenance and for replacement of all expendable components.

Manuals shall refer only to the actual equipment provided, all reference to alternative equipment shall be deleted.

All such literature shall be bound in new standard 3-ring binders and shall be submitted to the Engineer.

C. Include the items listed below and features as may be recommended by the manufacturers.

1. Catalog information of the unit installed.

2. Capacity and installation details.

3. Wiring diagrams of electrical components.

4. Special valves and control devices.

5. Complete list of parts with reordering numbers.

6. All points requiring lubrication, lubrication frequency and type of lubricant.

7. Operating pressure and temperatures.

8. Design pressures and temperatures.

9. Relief devices and settings.

10. Electrical characteristics of all motors.

11. Operating curves of pumps and fans.

12. Recommended spare parts list.

D. Prepare operating instructions, complete and explicit, including instructions for start-up, operating, and stopping. Underscore and emphasize critical points of operations and hazardous limit.

E. Items which also must be included are air handling HVAC components, fans, motors, plumbing items, pumps, relief valves, temperature control systems with a description of the sequence control, vibration isolator units, etc.


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F. Include flow charts and wiring programs in the manuals indicating valve locations and control devices. Also include parts lists to be used for ordering replacement and repair parts.

G. Arrange information in an orderly manner in accordance with the numbering system used for the Contract Specification.

H. Manual covers shall be printed and shall include the name of the Contract. The manual will be reviewed by the Commissioner prior to acceptance.

I. Maintenance Manuals:

1. Prepare maintenance manuals in accordance with Contract Documents. In addition to the requirements specified in Contract Documents, include the following information for equipment items:

a. Description of function, normal operating characteristics and limitations, performance curves, engineering data and tests, and complete nomenclature and commercial numbers of replacement parts.

b. Manufacturer's printed operating procedures to include start-up, break-in, and routine and normal operating instructions; regulation, control, stopping, shutdown, and emergency instructions; and summer and winter operating instructions.

c. Maintenance procedures for routine preventative maintenance and troubleshooting; disassembly, repair, and reassembly; aligning and adjusting instructions.

d. Servicing instructions and lubrication charts and schedules.

1.9 OPERATING AND MAINTENANCE DEMONSTRATIONS

A. General:

Provide instructions and demonstrations to designated operating personnel covering operation, adjustment and maintenance of mechanical work.

B. Coverage:

Operating personnel to gain a thorough knowledge and understanding of mechanical work. Instructions and demonstrations to include performance requirements, manufacturer's instructions and all phases of safe operation, control, adjustment and maintenance.

C. Instructor Qualifications:

Instructor to be competent technician in operation, adjustment and maintenance of each type mechanical work. When required, furnish product manufacturer's representative to provide instruction and demonstrations.

D. Service:

Furnish product manufacturer's factory trained representative to provide instructions and demonstrations when recommended by product manufacturer, required by installer, necessitated by project site conditions, or when product manufacturer guarantee is contingent upon such service.

1.10 PROJECT DRAWINGS OF RECORD

A. Maintain project record drawings in accordance with General Conditions, Technical Specifications Section 01781 and this Section. Shop drawings are not acceptable as record drawings.


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B. Show the following information on the Contract record drawings:

1. All significant changes in plan, sections, elevations, and details, such as all relocation, or changes in ductwork and piping.

2. All final locations of controls and final arrangement of electric circuits and any significant changes made in design as a result of change order or job conditions.

3. Final location and arrangement of all mechanical equipment.

4. Rerouting of existing piping.

C. Submit record drawings of underground mechanical piping furnished or relocated under this Contract.

The drawings shall be a minimum of 1 inch equal 20 foot scale. The drawings shall include pipe size, actual centerline elevations of pipe, and working point coordinates at each horizontal change in piping direction and valve box location.

Any existing piping temporarily supported to perform the Contract Work shall be shown as reference on the Contract record drawing.

Contractor shall confirm to the Owner that the above data and/or drawing is available for a piping system before the respective pipe trench is backfilled.


A. Applicable Publications

Reference made herein to standards, specifications, or codes, refer to the latest edition including all addenda, errata, or other revisions thereto, existing on the date of execution of the Contract.

B. Local Codes and Ordinances

Install all Work in conformance with all applicable local codes, State ordinances and statutes of the place of the Project. Nothing in the Specifications or Drawings shall be construed to permit deviation from the governing codes. In case of conflict with local ordinances and statues, the more stringent shall take precedent.

C. Standards and Abbreviations

Refer to Division 1, Section 01091 - Abbreviations and Symbols and under Mechanical Sections make use of the following abbreviations in adopting standards and codes as a part of Division 15:

ADC - Air Diffusion Council - Test Code

AGA - American Gas Association

AMCA - Air Moving and Conditioning Association

ANSI - American National Standards Institute

1. B16.1 - Cast Iron Pipe Flanges and Fittings

2. B16.3 - Malleable Iron Threaded Fittings.

3. B16.4 - Cast Iron Threaded Fittings

4. B16.5 - Steel Pipe Flanges, Valve Fittings

5. B16.9 - Factory-Made Wrought Steel Butt-Weld Fittings

6. B16.10 - Face-to-Face and End-to-End Valve Dimensions

7. B16.11 - Forged Steel Fittings


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8. B16.21 - Pipe Flange Gaskets

9. B16.25 - Butt Welding Ends

10. B16.34 - Valves-Flanged and Buttwelding Ends

11. B26.34 - Steel Butt-Welding End Valves

12. B31.1 - Power Piping

API - American Petroleum Institute

1. API 598 - Valve Inspection and Test

2. API 609 - Butterfly Valves, Lug-Type and Wafer-Type

ARI - Air Conditioning and Refrigeration Institute

ASHRAE - American Society of Heating, Refrigeration and Air Conditioning Engineers

ASME - American Society of Mechanical Engineers

ASTM - American Society for Testing and Materials

AWS - American Welding Society

AWWA - American Water Works Association

CGA - Compressed Gas Association

EPA - Environmental Protection Agency

FM - Factory Mutual System

IRI - Industrial Risk Insurers

MSS - Manufacturers Standardization Society

1. SP-44 - Steel Pipeline Flanges

2. SP-54 - Quality Standards for Steel Castings Radiographic Inspection Method for Valves, Flange Fittings and other piping Components

3. SP-58 Pipe Hangers and Supports

4. SP-69 Pipe Hanger Selection and Application

NEC - National Electric Code

NEMA - National Electrical Manufacturers Association

NFC - National Fire Code

NFPA - National Fire Protection Association

NPC - National Plumbing Code

OSHA - Safety and Health Standards

SMACNA - Sheet Metal and Air Conditioning Contractor's National Association, Inc.

TEMA - Tubular Exchangers Manufacturers Association

UL - Underwriters Laboratories, Inc.

1.12 PERMITS AND INSPECTIONS

A. Obtain and pay for all permits, bonds, licenses, tap-in fees, etc. required by the Owner.

B. Arrange and pay for inspections required by the above when they become due as a part of the Work of the Sections affected.


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C. Conceal no Work until approved by these governing authorities.

D. Present the Owner with properly signed certificates of final inspection before the Owner's acceptance of the Work.

E. Obtain and pay for all meters, gauges, instruments, and devices required by the governing authorities except, as otherwise noted, as part of the Work of the Sections affected.

1.13 GUARANTY

A. Except where otherwise specifically included in individual Sections, all mechanical systems shall be provided with the following guaranty:

B. Guaranty all mechanical systems, equipment, materials, and workmanship to be free from defect for a period of 1 year from the date of final payment of the Work.

Replace or repair in an approved manner the Work which may prove defective and/or not in compliance with the General Condition Guaranty without additional cost to the Owner and without interference with Owner's operations.

C. Deliver to the Owner two (2) copies of all manufacturer's or equipment suppliers' guarantee made out in the name of the Owner before final acceptance of the Work.

D. Make all adjustments required to ensure operation of the various systems in accordance with the intent of the Drawings and Specifications.

E. It shall be specifically understood that the making of adjustments to ensure the proper operation of the systems shall cover a period of 12 months following completion of the Work, and the Contractors and/or their suppliers shall make any or all adjustments required during this period without delay and without additional cost to the Owner.

F. Guarantee mechanical work meeting provisions of the Conditions of the Contract, except guarantee to include the additional provisions of this Article.

G. Guarantee to extend to corrections of the work found to be defective or nonconforming to the Contract Documents at no additional charge to the Owner.

Included: Damages resulting from such defects or non-conformance with the Contract Documents.

Excluded: Defects resulting from improper maintenance, operation, or normal wear.

Corrective work to be performed by original installer.

H. Time Period:

Repairs or replacement made to mechanical work within the guarantee period to be guaranteed for one year after final payment.

1.14 TRAINING OF THE OPERATING PERSONNEL

A. Provide the services of a competent supervisor or technician to instruct the Owner's personnel in the operation of each of the systems specified.

B. Include not less than one (1) full working day for each system unless otherwise noted in individual Section.

C. Where required by the individual sections of the specifications, provide the services of factory trained specialists to instruct the Owner's personnel in the operation of the system so specified.


Deliver products to the project properly identified with names, model numbers, types, grades, compliance labels, and other information needed for identification.


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1.16 JOB CONDITIONS

A. Pre-Installation Meetings:

1. Primary:

Owner may conduct a mechanical work pre-installation meeting at project site prior to start of mechanical work. Meeting shall include review of construction conditions, environmental requirements and coordination required for installation of the work, and responsibilities for temporary operation of permanent mechanical systems required for the work. Meeting participants shall include the Contractor, Engineer, Installers of mechanical work, electrical work and related project work, and product manufacturer representatives as necessary.

2. Other Work:

When required, installers of mechanical work to participate in other pre-installation meetings at project site to review conditions of other related project work. Assist in working-out conflicts, interferences, adjustment and responsibilities.

B. Manufacturer's Representative:

Furnish installation assistance of product manufacturer's factory trained representative to give installation instructions, assist in start-up operations, direct acceptance inspections and tests, and perform like services at project site as required.

C. Existing Conditions:

Existing Construction: Remove, reroute or alter existing structures, piping, equipment, etc. as required by the Contract Documents.

D. Structural Components:

Do not cut, drill or weld existing structures for attachment of mechanical work without prior review by Owner of each condition, except where specifically indicated.

Requests for authorization to be in writing, designating specific extent and limits of work, and components proposed to be cut, drilled or welded.

E. Coordination:

Coordinate mechanical work with other project work. Changes required in mechanical work due to lack of coordination shall be at no additional charge to the Owner.

PART 2 - PRODUCTS

2.1 EQUIPMENT SUPPLIED BY CONTRACTOR

A. Contractor furnishing an item of equipment, including pre-purchased equipment, is responsible for the proper handling, setting, installation, start-up and initial operation.

B. If Contractor is unfamiliar with the proper start-up and adjustment procedure of any equipment or system furnished by it, the Contractor shall include services from a qualified representative of the manufacturer or vendor to provide start-up assistance and for instruction of Owner's personnel.

C. Contractor shall include all necessary allowances to insure that all equipment and systems furnished will be serviced as required during the guaranty period.

D. When a manufacturer offers an extended warranty at additional cost, such extended warranty shall be included as alternate.


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E. All equipment and material to be new, undamaged, and of the best grade of manufacture; decisions concerning quality, fitness of materials, or workmanship to be by the Owner and Engineer.

F. Where items exceed one in number provide products with identical construction, model numbers, and appearance, from the same manufacturer.

G. In so far as possible, products to be the standard design of the manufacturer.

Manufacturer shall have been engaged in the manufacture of the product for a minimum of five years.

When standard products are modified to suit these Contract Documents, manufacturer to certify operating conditions, ratings and capacity of the product and Contractor to submit compliance certificates.

H. Acceptable Products:

Certain makes and/or manufacturers of material and equipment are specified herein and/or indicated on the accompanying Drawings as Acceptable Products.

Prior to submittal, use manufacturer's published data to verify that the product meets the Specification.

Notify the Owner of conflicts.

2.2 OPERATING INSTRUCTIONS TO THE OWNER

A. Provide the services of a competent supervisor or technician to instruct Owner's personnel in the operation of each type of system.

B. Include not less than one full working day for each system.

C. Where required by the individual mechanical sections of these Specifications, provide the services of factory-trained specialists to instruct Owner's personnel in the operation of special systems.

D. Include a minimum time for instruction as required under that Section.

PART 3 - EXECUTION

3.1 SAFETY PRECAUTIONS DURING INSTALLATION

A. Contractor shall take all measures to ensure safe installation of all Work and to prevent injury to persons or damage to property in compliance with OSHA and all applicable regulations.

B. Contractor shall erect whatever scaffolds, platforms, supports, or other required construction to safely protect its own workers and other persons at the site.

C. Such scaffolds, platforms, etc., shall be designed and constructed by Contractor who shall be solely responsible for their adequacy and safety.

The Owner is not responsible for ascertaining the adequacy of any temporary structures used or erected by the Contractor.

3.2 START-UP AND TESTING OF EQUIPMENT

A. Contractor is responsible for testing, start-up and adjustment of all equipment and shall employ the services of factory trained technicians to provide such services as are needed for proper commissioning of the entire system.

B. When a specific testing procedure is prescribed by the manufacturer, all instrumentation required to perform the test shall be supplied by the Contractor.


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C. Performance tests shall be conducted for the following equipment: Building Facilities equipment Boiler Pumps Controls Air Handling & Heating equipment as called in each Section or as recommended by the manufacturer. Process Mechanical Systems equipment, pumping systems, storage systems, etc.

D. All equipment tested shall be in accordance with Local Building Code where applicable.

3.3 ROUGH-IN

A. Verify final locations for rough-ins with field measurements and with the requirements of the actual equipment to be connected.

B. Refer to equipment specifications in Divisions 2 through 16 for rough-in requirements.

3.4 MECHANICAL INSTALLATIONS

A. General: Sequence, coordinate, and integrate the various elements of mechanical systems, materials, and equipment.

Comply with the following requirements:

1. Coordinate mechanical systems, equipment, and materials installation with other building components.

2. Verify all dimensions by field measurements.

3. Arrange for chases, slots, and openings in other building components during progress of construction, to allow for mechanical installations.

4. Coordinate the installation of required supporting devices and sleeves to be set in poured-in-place concrete and other structural components, as they are constructed.

5. Sequence, coordinate, and integrate installations of mechanical materials and equipment for efficient flow of the Work.

6. Give particular attention to large equipment requiring positioning prior to closing in the building.

7. Where mounting heights are not detailed or dimensioned, install systems, materials, and equipment to provide the maximum headroom possible.

8. Coordinate connection of mechanical systems with exterior underground and overhead utilities and services. Comply with requirements of governing regulations, franchised service companies, and controlling agencies. Provide required connection for each service.

9. Install systems, materials, and equipment to conform with approved submittal data, including coordination drawings, to greatest extent possible. Conform to arrangements indicated by the Contract Documents, recognizing that portions of the Work are shown only in diagrammatic form. Where coordination requirements conflict with individual system requirements, refer conflict to the Engineer.

10. Install systems, materials, and equipment level and plumb, parallel and perpendicular to other building systems and components, where installed exposed in finished spaces.

11. Install mechanical equipment to facilitate servicing, maintenance, and repair or replacement of equipment components. As much as practical, connect equipment for ease of disconnecting, with minimum of interference with other installations. Extend grease fittings to an accessible location.

12. Install access panel or doors where units are concealed behind finished surfaces.


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13. Install systems, materials, and equipment giving right-of-way priority to systems required to be installed at a specified slope.

B. Painting:

1. Prime and paint all ferrous metal surfaces not already suitably primed and painted except galvanized, plated or machined surfaces, insulating unions and dielectric flange gaskets, nameplates, tags, labels, or explosion proof items.

2. Paint items suitably primed and touch-up items furnished painted to provide a uniform protective coating system.

3. Meet manufacturer's instructions and recommended procedures.

C. Clean Up:

1. Prior to acceptance tests and inspections, clean the project site.

2. Remove all miscellaneous construction equipment, dispose of all trash and unnecessary excavated material in a manner acceptable to the Owner or his authorized representative.

3. Make the site as safe, clean and completely finished as possible.

D. Inspections and Tests:

1. General:

Test all of the equipment and piping installed under this Specification and demonstrate its proper operation to the Owner or his authorized representative; furnish all required labor, testing, instruments and devices required for tests and pay for all expenses involved in conducting such tests. If tests show work or equipment to be defective, immediately make all changes necessary to correct work and performance to the satisfaction of the Owner or his authorized representative; give 48 hours notice, by letter or fax, to the Owner or his authorized representative of all tests and demonstrations; provide safe access to the test area if the work is in preparation or in progress. Contractor to be given reasonable times to correct defects; if such correction of defects or performance requirements are neglected, the right is reserved to have defects remedied and to charge the cost of same against the account of the Contractor.

2. Inspection:

Inspection Includes But Is Not Limited To:

a. Alignment: Check whether equipment has been aligned.

b. Lubrication: Check lubricant types and levels.

c. Tightening: Tighten bolts, capscrews and other fasteners.

d. Safety Guards: Check safety guards.

3. Start-up: Perform equipment start-up meeting requirements of equipment manufacturer; if manufacturer's representative is required to be present, coordinate with same; start-up to be made without load, except when detrimental to equipment.

4. Final Condition: Before final acceptance, top-off all fluids, check all connections, and remove all remaining debris.


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E. Equipment Installation Acceptance: 1. General:

Equipment installation will be accepted by Owner or his authorized representative after running equipment under load in permanent operation.

2. Additional Work: After equipment installation acceptance and when requested, perform work to correct deficiencies or improper operation of equipment. Additional work will be paid on basis of contract conditions relative to changes in work. Payment shall be excluded for work relative to time spent correcting deficiencies or improper operation of equipment covered under the work.

3.5 CUTTING AND PATCHING A. General:

Perform cutting and patching in accordance with Contract Documents. During cutting and patching operations, protect adjacent installations.

B. Perform cutting, fitting, and patching of mechanical equipment and materials required to:

1. Uncover Work to provide for installation of ill-timed Work.

2. Remove and replace defective Work.

3. Remove and replace Work not conforming to requirements of the Contract Documents.

4. Remove samples of installed Work as specified for testing.

5. Install equipment and materials in existing structures.

6. Upon written instructions from the Architect, uncover and restore Work to provide for Architect/Engineer observation of concealed Work.

C. For selective demolition and non-destructive removal of mechanical material and equipment, see Division 2 of Specifications section.

3.6 ALTERATIONS IN PRESENT BUILDING AND SITE Take particular note of the revisions and alterations of existing services, utilities, etc., due to the new construction as indicated on the Drawings and/or as required by alterations to the existing building.

3.7 DISPOSITION OF REMOVED EQUIPMENT A. Where existing materials or equipment are specified to be removed from service,

Contractor shall take possession of same and remove them from the site promptly, except as specified below or unless otherwise noted on Drawings.

B. All salvageable material and equipment, including but not necessarily limited to, conduit, wiring, plumbing fixtures, heating units, piping, valves, etc., shall be removed and maintained in as good condition as possible and turned over to the Owner.

C. However, if Owner decides any such materials are of no value, then they shall become the property of the Contractor who shall remove such discarded work from the premises and dispose of same.

END OF SECTION


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BASIC MECHANICAL PROCEDURES & METHODS 15011-1

SECTION 15011

BASIC MECHANICAL PROCEDURES & METHODS

PART 1 GENERAL

2.1 SCOPE OF WORK

A. Except where otherwise specifically included in other Sections, all mechanical equipment, plus materials furnished and installed under Division 15, shall be in accordance with the requirements under this Section.

B. The Contractor is responsible for providing all electrical Work for all systems as specified or as required or as shown on the Drawings for a complete fully integrated operating system. Equipment is specified without and with factory wired equipped disconnect switches, manual/automatic starter equipment and accessories. For equipment specified without factory wired equipped disconnect switches, manual/automatic starter equipment and accessories, Contractor shall also be responsible for providing wiring, disconnect switches, manual/automatic starter equipment and accessories as shown on the drawings or as specified or as required for a complete fully integrated operating systems. All in accordance with applicable Specification, Division 16 - Electrical. It shall be the Contractor's responsibility to obtain equipment data from the various equipment supplier and to prepare diagrams incorporating equipment data as necessary and to coordinate all electrical requirements.

2.2 DESCRIPTION

A. This Section defines the furnishing and installing of mechanical equipment, materials, and workmanship under Division 15.

B. Any interruptions and tie-ins to existing systems that are necessary for installation of the new Work shall be performed and completed in the time period specified in the Contract Documents.

2.3 MODIFICATIONS AND INTERFERENCES

A. Contractor shall carefully check and become familiar with the Architectural, Structural, Electrical and all Mechanical Drawings and Details and make note of all locations where walls, partitions, ceilings, and structural members are called for to be furred or closed-in.

B. Modifications to the arrangement of the piping systems may be required to suit structural conditions, or to avoid interference with the Work of other trades. Contractor shall furnish all offsets, additional fittings, etc., as required to meet installation conditions whether detailed on the Drawings or not.

C. Any conflicting information in the Specifications or on the Drawings shall be called to the attention of the Engineer for clarification before proceeding with fabrication or erection of the parts affected.

If, in the opinion of the Engineer, any additional detail Drawings are necessary, Contractor shall prepare them at Contractor's own expense, together with all bills of material.

2.4 ARRANGEMENT AND ALIGNMENT

A. All piping shall be arranged and aligned as indicated on the Drawings, and without conflict with the other piping. Elevations, as given, must be as close as possible. Floor elevations, where given, are to high points of floor. Dimensions must be held as closely as possible. All dimensions are to be field-checked for accuracy before pipe is fabricated.


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B. Install all piping straight and direct as possible, generally forming right angles with, or running parallel with, walls or adjacent piping. All piping shall be neatly spaced with risers and drops running plumb and true.

C. Run piping in wall chases, pipe shafts, hung ceilings, recesses, etc., where same are provided. Do not run service piping in floor slab fill unless specifically so noted on Drawings. Piping shall not be covered or closed until testing is completed, except the outdoor buried piping.

D. Drawings, in general, are made based on available information. All dimensions shall be checked in the field by the Contractor before final connections are fabricated.

E. Drawings for small piping are, in general, diagrammatic and the exact location of these lines shall be determined by the Contractor from field measurements taken by it. The actual arrangement of the small size piping, when erected, shall follow the general locations shown on the Drawings as far as practicable. The installation made in this way shall be neat in appearance and convenient to operate, and shall provide for proper expansion and drainage.

F. Installation of piping systems shall be coordinated with other Work to avoid blocking building openings, light fixtures, etc. Piping shall not interfere with access to valves or equipment and shall not obstruct passageways. Piping shall be installed to provide working clearance for operation and maintenance.

2.5 PIPE INSTALLATION

Unless otherwise specifically specified in other Sections, or shown on the Drawings, all piping shall be installed in accordance with the following:

A. All drip pan or drain piping shall be installed with a slight pitch so that they can be completely drained. Minimum pitch shall be 1" in 40'-0".

B. All steam and condensate return piping shall be installed with a pitch of 1" in 40'-0" in the direction of flow.

C. All water piping systems and equipment shall be provided with valved drains piped to floor drains or open wastes.

D. All foreign substances must be removed from the interior of any piping before pipe is installed.

E. Threads in screwed piping shall be right hand, pipe standard, full depth and tapering. Pipe shall be reamed full size after cutting and threading.

F. Joints in threaded pipe installations shall be made tight without caulking or the use of lead or paint; threaded joints in plastic, stainless steel and chlorine service piping shall be made up with teflon thread tape applied to all male threads; at the option of the Contractor, threaded joints and other piping may be made up with thread tape or Dixon's Compound or key paste, and the lubricant shall be applied to male threads only. No lubricant shall be used except flake graphite and cylinder oil paste.

G. Piping between fittings must be continuous wherever possible. If, however, the distance between fittings exceeds the normal random length of pipe, and couplings must be used, they shall be heavy recessed couplings of the same material as the pipe to which they are attached.

H. Reductions in threaded pipe sizes shall be made with the proper reducing fittings for the particular application. The use of threaded bushings is not permitted.


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I. Final connections to equipment 2-1/2" and larger shall be flanged. It is the responsibility of the Contractor to provide flanged outlets on equipment connections 2-1/2 inches and larger, if required. Connections 2 inches and smaller shall be made with solder joints, screwed unions or union fittings, whichever is appropriate.

J. In screwed pipe installations, provide a union at each screwed valve, strainer, and elsewhere as indicated on the Drawings or wherever required for the proper servicing of equipment and accessibility.

K. The use of close or short screwed pipe nipples must be avoided wherever possible; however, if roughing-in dictates the use of close or short nipples, they must be of extra heavy Schedule 80 pipe of the same materials as adjoining pipe.

L. Wherever two (2) or more pipes are to be installed in parallel, or parallel to the piping of other trades, the piping shall be installed with minimum clearance of three (3) inch space between pipes to allow for the proper application of pipe covering, painting and/or servicing.

M. In no case shall any pipe be installed where it is supported on or suspended from another pipe or the piping of other trades.

N. When necessary to fit or center with windows and door openings, Contractor shall, at its own expense, shift and relocate outlets, roughing-in, etc., as directed by the Engineer.

O. Where automatic valves are installed of either pressure, pneumatic, capillary or electric type, and for control purposes, the valve size becomes smaller than the pipe size marked on the Drawings, it is to be understood that the reduction in size pertains to the automatic control valves and manual control valves only. Gate valves and strainers on either side of the automatic valves shall be a minimum of the pipe size marked on the Drawings. Reductions, where necessary on account of automatic valve size, shall be made with the proper reducing fittings, immediately adjacent to the inlet and outlet of the control valves.

P. Where suction or discharge of any pump unit is smaller than the pipe size noted on the Drawings, reducing fittings shall be provided at the pump connections only. All strainers, valves, and flexible connection sizes shall be minimum pipe size, unless noted on the Drawings.

Q. Dirt pockets shall be provided at the ends of connections to steam traps, water and steam type heating coils, and convertors. Dirt pockets at main ends shall be, as a minimum, the size of the pipe connections to the equipment. Dirt pockets shall be not less than 8 inches deep and ends shall be provided with removable caps.

R. Where sensing control elements and/or thermometer wells are installed in any piping system, the piping shall be enlarged as required by the cross sectional area of the wells. Pipe sizes shall not cause constriction in the piping where said wells are installed.

S. Provision shall be made as shown on the Drawings, or as required, providing expansion joints, loops, and swings, to relieve any undue strain or thrust on any piping or items of equipment. Anchors shall be provided and located as shown on the Drawings, or as specified to control directional expansion.

T. In all cases where pipe connections are made to piping or any item of equipment of dissimilar metal, install the proper type of dielectric fitting. Insulating unions shall be provided only for piping 2" dia. and smaller.

U. Prepare pipe, fittings, supports, and accessories for finish painting. Refer to Section 09928.

V. Install valves with stems upright or horizontal, not inverted.

W. Piping shall be installed with sufficient space between pipes to allow for the proper application of pipe covering, painting and/or servicing.


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X. Install unions downstream of valves and at equipment or apparatus connections.

Y. Process mechanical system piping shall be in accordance with specifically specified and applicable sections.

2.6 ALIGNMENT OF ROTATING EQUIPMENT

Unless otherwise specifically specified in other section or shown on the Drawings, all alignment of rotating equipment shall be in accordance with the following:

A. All pumps or similar equipment directly connected to motors by means of flexible couplings must be perfectly aligned after installation by the use of a dial indicator, and the Work of alignment must be performed by a craftsman skilled in the Work.

B. Belted equipment shall be aligned so that the grooves of the driver pulley are truly aligned with those of the driven sheave, and the belts must be in the proper tension, free from flutter. In multi-belt drives, all belts must be operated at the same plane. Flutter in any one (1) belt will be cause to reject the entire set, as the original installation of belts must be in matched sets.

C. All equipment provided with high capacity belt drives must be conveniently tagged and so identified for future servicing and replacement of belts.

D. Before any rotating equipment is put in operation for testing purposes, it shall be properly lubricated with lubricants only as recommended by the manufacturer and they shall be further lubricated before the equipment is turned over to Owner.

2.7 PIPE WELDING AND WELDING CONNECTIONS

Unless otherwise specifically Specified in other Sections or shown on the Drawings all carbon steel piping, wherever specified for any service 2-1/2" and larger, shall be fabricated and assembled with welded joints and connections in accordance with the following:

A. All welders and welding procedures shall be certified in accordance with the procedures of the National Certified Pipe Welding Bureau, and approved procedures conforming to the requirements of the ASME Boiler and Pressure Vessel Code, Section IX and ANSI B31.1. No welder shall be employed on the Work who has not been fully qualified under the herein specified procedures and so certified by a member of the local chapter of the National Certified Pipe Welding Bureau or similar testing authority.

B. Welding of piping 2 inches and smaller shall be by oxyacetylene method, and welding of piping 2-1/2" and larger shall be by micro-wire or shielded electric arc method. Weld neck flanges shall be provided at flanged connections on piping 2-1/2" and larger. Welding rod for oxyacetylene method shall be Tensox, mild steel welding rod as manufactured by Central Steel and Wire, Chicago, Illinois, or approved equal, and shall be Fleetweld #5 as manufactured by Lincoln Electric, or approved equal, for electric arc welding. Micro-wire shall be of type suitable for use with the piping material.

C. Where permitted, openings cut into pipe for welded connections shall be accurately made to provide carefully matched intersections.

D. Long radius elbows shall be used at all turns in welded piping. Mitered elbows on 12" and smaller pipe will not be permitted.

E. Abutting ends of joints shall be separated before welding by the thickness of 1/8 inch welding rod tacked in at least four (4) points to maintain alignment. Welding back-up rings shall be used on piping 6" in size and larger, where pipe is welded by any method other than micro-wire welding.


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F. Shielded electric arc welds shall be of single Vee butt type for which pipe shall be mill or machine beveled at 34-1/2" degrees to within 1/16" of inside pipe wall. Each weld shall be made with three (3) passes; a stringer bead, a fill-in bead bringing weld flush with pipe, and a final wash or lace pass.

G. Where welding branches or connections are taken from a branch or main and the branch or the connection pipe size is equal to or greater than one-half the diameter of the main, a welding tee must be installed in the main for the branch or connection.

H. Where branches or connections are made to a welded main and the branch or connection is less than one-half the diameter of the main, and the branch is 2-1/2" and larger, provide a Bonney-Forge Weldolet, or approved equal, at the branch connection to the main, and where the branch or connection to the main is 2 inches and smaller, provide a Bonney-Forge Threadolet, Sockolet, or approved equal, at the branch connection to the main. Screwed couplings, half couplings or screwed nipples welded to mains for screwed branches will not be permitted.

I. The method of attaching Weldolet and Threadolet units, or approved equals, to piping shall be in strict accordance with ANSI B-31.1, Section 6, Paragraph 63B of the American Standard for Steel Butt-Welding Fittings.

J. Full lengths of pipe shall be used wherever possible. Short lengths of pipe with couplings will not be permitted.

K. All pipe shall be cut to exact measurement to be installed without forcing. After cutting, ends shall be reamed and cleaned to eliminate foreign matter.

L. Cutting or other weakening of the building structure to facilitate piping installation will not be permitted.

M. All pipe and fittings shall be marked by the manufacturer in accordance with requirements of MSS SP-25.

N. Make all changes in size and direction of piping with fittings. Do not use bends, miter fittings, face or flush bushings, street elbows, or field-fabricated reducers.

O. Close nipples shall not be permitted; use only shoulder nipples. Shoulder nipple with shoulder length less than 1-1/2" shall be of heavy wall pipe; nipples having shoulder length of 1-1/2" or greater shall be of same schedule as connected pipe.

P. Tack welds used in assembly of pipe and fittings shall be made by a qualified welder or shall be removed. Tack welds, which are not removed, shall be made with an electrode which is the same as or equivalent to the electrode to be used for the first pass. Tack welds must be thoroughly cleaned, ground smooth, carefully examined for cracks, and all cracks removed before additional metal may be deposited. No metal shall be tack-welded inside pipe for alignment purposes.

2.8 CONNECTIONS TO EQUIPMENT AND SPECIALTIES

Unless otherwise specifically specified in other Sections or shown on the drawings, all the connections to equipment and specialties shall be in accordance with the following:

A. Piping systems shall be installed complete to equipment connections or terminal use points.

B. Piping shall be fabricated carefully and accurately to meet connections on equipment without springing the pipe.


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C. Provide unions or flanges at all piping connections to coils, equipment, control valves, pressure reducing valves, steam traps, etc., at all locations as shown on the Drawings, and generally as required to disconnect piping from equipment and apparatus. Arrange connections so that the equipment served may be removed without disturbing the piping. Where valves serve to isolate equipment or specialties, the unions or flanges shall be located between valves and equipment or specialties. Unions shall generally be used for pipe sizes 2 inches and smaller and flanges for pipe sizes 2-1/2" and larger.

2.9 PIPE CLEARANCES

Unless otherwise specifically specified in other Sections or shown on the Drawing, install piping to provide minimum clearance of at least one (1) inch between extreme projections of piping, flanges, fittings, valves, allowing for insulation, pipe expansion, etc.

2.10 PIPING EXPANSION

Special attention shall be given to the installation of hot and cold lines which have an appreciable movement so that they will not hit other pipes, structural members, etc., when they heat up or cool.

2.11 SOLDERED AND BRAZED PIPING JOINTS

A. All soldered and/or brazed joints shall meet the particular application requirements and shall be made in accordance with good practice. Tube ends shall be square cut and reamed, straightened and rounded with straightening tools as necessary.

B. Fitting and tube surfaces shall be properly cleaned with steel wool or emery cloth and a suitable flux shall be used in accordance with manufacturer's recommendations. Uniform heat shall be applied by the use of blow torch, electric joint heater, or oxyacetylene torch. Adequate cooling time shall be allowed before washing or quenching. Appurtenances that are fragile or heat sensitive shall be protected against over-heating, or the sensitive parts shall be removed during this application of heat.

C. All soldered joints for low temperatures (less than 250oF) service shall be made using 95-5 Tin-Antimony solder metal for indoor service and flared joint for buried service, unless otherwise specified, or for other services.

D. All brazed joints shall be made using Silfoss or silver solder, or unless otherwise specified.

2.12 PREFORMED PIPING JOINTS

Where ASTM C 425 joints are used, they shall be wiped clean and the solvent applied in accordance with ASTM procedures.

2.13 MECHANICAL PIPING JOINTS

Clean spigot and bell with wire brush. Brush surfaces and gasket with soapy water. With gland and gasket in place on spigot, insert into bell. Seat spigot in bell and press gasket into bell and pull gland against bell. Install bolts and nuts fingertight. Finish with a torque wrench, range 60 to 90 pounds or as recommended by pipe manufacturer.

2.14 VALVES - BUILDINGS SERVICE SYSTEMS

A. All valves shall comply with the Schedule or Legend on the Drawings.

B. Make provisions for draining low points of all water piping systems, whether indicated on the Drawings or not, using a globe valve and iron pipe thread to hose thread adapter. Drains shall not be less than 3/4 inch, subject to sizes indicated on Drawings.


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2.15 LOCATION OF VALVES AND PIPING COMPONENTS

A. System components which required observation, operation, or maintenance - such as valves, gages, controls, strainers, dirt pockets, cleanouts, unions and flanges, etc., shall be located, whenever possible, so as to be readily accessible. They shall not be concealed in chases or above ceilings without provision for access. Valves which require frequent operation, or which may require emergency operation, and which are not accessible from normal working level, should be installed with appropriate provisions such as chain wheels or extension stems.

B. Install all valves with stems in either an upright (preferred ) or horizontal position. Control valves shall be installed with top works upward unless specifically shown otherwise.

C. Globe valves should be installed to seat against the direction of flow.

2.16 DRAINAGE AND VENTING

Where lines are purposely pitched for drainage or venting, an accurate grade shall be maintained. Lines shall be supported in such a manner as to prevent deflection of the piping sufficient to pocket the lines.

2.17 PIPE SIZE DESIGNATIONS

All pipe sizes referred to in these Sections should be interpreted as IPS (iron pipe size) unless specifically designated otherwise.

2.18 CUTTING AND PATCHING

A. All cutting, repairing, fitting, and refinishing of in-place construction required for the installation of the Work of a Section, shall be included as part of the Work of that Section except as specifically shown on Drawings or hereinafter specified.

B. Work shall be performed by craftsmen skilled in their respective trades.

C. Match existing conditions in color, materials, and texture.

2.19 NOISE AND VIBRATION CONTROL

A. Contractor shall make provisions in the installation of its Work that noises or vibrations will not be transmitted through foundations, floors, walls, columns, ducts and piping, so as to be objectionable in any manner. All equipment provided shall be selected and installed with this in view. If any equipment exceeds reasonable requirements as to quietness of operation and freedom from vibration when operating under continuous maximum demands, it shall be altered or replaced.

B. Furnish and install vibration eliminators and isolation equipment as manufactured by the Vibration Eliminator Co., Korfund, Mason Industries, or approved equal, for equipment, motors, and pumps, as indicated on the Drawings, or as specified.

C. The isolation and vibration eliminator manufacturer and Contractor shall be responsible for the selection of the proper units for their loadings, quantities, and each shall guaranty that each and every installation and their application shall have a vibration efficiency of 95% or greater. As a minimum, provide types of vibration eliminators as indicated on the Drawings.

D. Submit shop drawings to Engineer for review of all isolation equipment with dimensions and other data as recommended and prepared by the isolation equipment manufacturer.

2.20 GUARDS

A. Except where otherwise specifically in other sections, all belt, pulleys, chains, gears, couplings, projecting set screws, key and other rotating parts shall be fully enclosed and properly guarded.


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B. Guards shall be constructed as specified, shown on the Drawings otherwise shall be of not less than 1" x 1" x 1/8 inch structural steel angles and 1/2 inch diamond mesh enclosure or equally suitable enclosure, all of hot- dipped galvanized fabrication.

C. Guards shall be secured to the driven machines or to foundations of floors by heavy galvanized structural angle supports and anchor bolts. Braces or supports secured to motors will not be permitted and braces and/or supports must not "bridge" the sound and vibration isolators.

D. Guards shall be designed with adequate provision for movement of motor required to adjust belt tension. Means shall also be provided to permit lubrication, use of speed counters and other maintenance and testing operation with guard in place.

2.21 GROUTING FOR MACHINERY BASES

A. Except where otherwise specifically included in other Sections, all machinery bases shall be grouted as specified herein.

B. Provide necessary grouting for all steel and cast iron bases for water pumps and other equipment requiring same.

C. Grout shall be in accordance with Section 03605 – Nonshrink Grout, unless otherwise specified under other Sections.

D. Grout shall be introduced into equipment base plates and shall be well rodded in place to prevent any air cavities forming during placement of grout.

2.22 PIPING PRESSURE TESTS - BUILDING SERVICE SYSTEMS

A. Except where otherwise specifically included in other Sections, each piping system shall be tested as specified herein.

B. Each piping system shall be tested by the trade responsible for the Work, under the supervision of the Owner or Owner's representative.

C. As portions of the mechanical systems are completed, the following tests shall be performed in the presence of the Owner or Owner's representative.

The Engineer shall be given forty eight (48) hours advance notice "in writing" of the proposed time of all tests.

1. Provide all necessary pumps, gages, instruments, test equipment and personnel required for performing the tests. Remove testing equipment after completion and acceptance of tests.

2. Piping:

a. All piping and connections shall be subjected to a pressure test prior to flushing, cleaning, painting, installation of insulation, or concealment within the building.

b. The test pressure shall be not less than 50% in excess of the pressure to which the pipe will ordinarily be subjected unless otherwise specified.

c. All pressure pipe shall be subjected to a test pressure of not less than 150 psi unless otherwise specified in the test pressure schedule.

d. Tests may be made of isolated portions of such piping as will facilitate general progress of the installation.

e. Any revisions made in the piping system subsequently will necessitate retesting of such affected portion of the piping systems.

3. All defective material or defects in workmanship that develop during the tests shall be corrected in an approved manner and the subject piping retested.


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D. Tests shall be made as follows:

1. Service Water Piping:

a. Subject to a hydrostatic test pressure of not less than 200 psig. Test shall demonstrate fitness of piping installation to hold required pressure for a period of not less than 2 hours.

2. 15 psi Steam and Condensate Return:


3. Feedwater Make-up, Boiler Chemical Feed and Heating System Water Piping:


4. Safety Valve Vent & Relief Valve Discharge:


5. Propane Gas / Natural Gas:


2.23 CLEANING AND FLUSHING OF PIPING SYSTEMS

A. Except where otherwise specifically included in other Sections, all piping systems shall be cleaned as specified herein.

B. Piping systems and equipment shall be thoroughly cleaned after pressure testing and flushing to the complete satisfaction of the Engineer.

C. Prior to pressure testing, the Contractor shall provide all necessary valved connections, temporary cross connections to the new piping systems for fill, drainage and cross-connections, as required, to facilitate complete cleaning operations.

D. After cleaning, all temporary piping shall be removed and the connections on the piping shall be capped and sealed with materials and procedures as outlined for the respective systems.

E. Tests will be conducted by Owner to verify that the cleaning programs conducted by the Contractor have removed all foreign materials from the piping systems and equipment.

F. All new water piping systems shall be flushed using water. Low point drains shall be opened and the systems proved to be drainable.

G. The new steam heating system boiler, condensate return pump sets, boiler feedwater units, etc. shall be flushed independently from their piping systems.

H. Submit data and procedure to be used in the cleaning process for review by the Owner or Engineer before beginning any cleaning operation.

Secure a signed acceptance from Engineer after completion of each cleaning and water treatment operation.


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2.24 OPERATING TESTS

A. Except where otherwise specifically included in other Sections, prior to testing, all equipment shall be properly lubricated in accordance with the manufacturer's instructions.

B. Except for small electrical motors which, under NEMA Standards, are equipped with lifetime lubrication, all bearings on large motors and mechanical equipment shall be equipped with lubrication fittings at all service points, accessibly located. Oil fill and drain line extensions shall be provided where necessary for convenient servicing of equipment.

C. Each piping system shall be tested by the trade installing the Work under the supervision of the Owner or Engineer.

D. After the various systems are pressure-tested, cleaned and the water chemically treated as hereinbefore specified, the following tests shall be made in the presence of the Engineer:

1. Five (5) days' advance "written" notice of the tests shall be given to the Engineer who, in turn, will notify other interested parties.

2. Furnish all gages, instruments, test equipment and personnel required for the tests.

3. Adjust all equipment to perform with the least possible noise and vibration consistent with its duty.

4. Quietness of operation of all equipment is a requirement.

5. Any equipment producing noise that is abnormal, in the opinion of the Owner or Engineer, shall be repaired or removed and replaced with satisfactory equipment at no additional expense.

E. Piping systems:

Operate the system and make all adjustments in control and equipment and complete necessary balancing to deliver not less than the fluid quantities shown on the Drawings for each equipment item.

2.25 PIPE AND EQUIPMENT IDENTIFICATION

Piping identification shall be as specified in Section 15190- "Mechanical Identification". Equipment identification consistent with the markings on the equipment schedule shall be made following finished painting with paint or stencil letters or numerals as approved by the Commissioner.

2.26 CLEANING - GENERAL AREA

A. Contractor shall assist in maintaining the premises in an orderly fashion at all times, providing continuous clean-up during the construction period. Contractor shall remove all cartons, containers, and crates as soon as their contents have been removed and shall also remove all debris caused by its Work as soon as possible. Deposit all discarded materials in a suitable refuse container and prevent these materials from being scattered by the elements. All cartons and debris shall be removed from the premises and site at the sole expense of the Contractor.

B. Contractor shall stack all construction materials associated with its Work in areas so as to avoid congestion and interference.

C. At the completion of the Work, the Contractor shall clean all of its Work and equipment free from dust and other foreign matter and shall leave the Work in good house-keeping fashion, in a manner acceptable to the Engineer.


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2.27 WIRING DIAGRAMS

Contractors shall provide each major piece of electrically connected, controlled, or operated equipment with specific wiring diagrams and instructions. Diagrams and instructions shall not be of a general or typical nature but applicable only to the specific job. The diagrams and instructions used to install the equipment shall be identical to that included in the "Operations and Maintenance Manuals".


A. Follow manufacturer's directions in the delivery, storage, protection and handling of all equipment and materials.

B. Deliver and store equipment and materials to the site on original containers, sheltered form the elements and mechanical injury. Items subject to moisture damage shall be stored in dry, heated spaces.

C. Ascertain whether any temporary access openings in the building will be required for the admission of apparatus and notify Construction Manager and the Architect's representative accordingly.

D. Contractor shall not rig to; tie to; or rest weight upon any part of the building or make use of the stairway until specific permission is obtained.

PART 2 PRODUCTS

2.1 MISCELLANEOUS METALS

A. Steel plates, shapes, bars, and bar grating: ASTM A 36.

B. Cold-Formed Steel Tubing: ASTM A 500.

C. Hot-Rolled Steel Tubing: ASTM A 501.

D. Steel Pipe: ASTM A 53, Schedule 40 welded. Use Schedule 80 for steam condensate piping.

E. Nonshrink, Nonmetallic Grout: Premixed, factory-packaged, non-staining, non-corrosive, nongaseous grout, recommended for interior and exterior applications.

F. Fasteners: Zinc-coated, type, grade, and class as required.

2.2 JOINT SEALERS

A. General: Joint sealers, joint fillers, and other related materials compatible with each other and with joint substrates under conditions of service and application.

B. Colors: As selected by the Architect from manufacturer's standard colors.

C. Elastomeric Joint Sealers: Provide the following types:

1. One-part, non-acid-curing, silicone sealant complying with ASTM C 920, Type S, Grade NS, Class 25, for uses in non-traffic areas for masonry, glass, aluminum, and other substrates recommended by the sealant manufacturer.

2. One-part, mildew-resistant, silicone sealant complying with ASTM C 920, Type S, Grade NS, Class 25, for uses in non-traffic areas for glass, aluminum, and nonporous joint substrates; formulated with fungicide; intended for sealing interior joints with nonporous substrates; and subject to in-service exposure to conditions of high humidity and temperature extremes.

3. Available Product: Subject to compliance with requirements, products which may be incorporated in the Work include, but are not limited to, the following.


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4. Products: Subject to compliance with requirements, provide one of the following:

a. One-Part, Non-acid-curing, Silicone Sealant:

1) "Chem-Calk N-Cure 2000," Bostic Construction Products Div.

2) "Dow Corning 790," Dow Corning Corp.

3) "Silglaze N SCS 2501," General Electric Co.

b. One-Part, Mildew Resistant, Silicone Sealant:

1) "Dow Corning 786," Dow Corning Corp.

2) "SCS 1702 Sanitary, " General Electric Co.

3) "863 #345 White," Pecora Corp.

D. Acrylic-Emulsion Sealants: One-art, nonsag, mildew-resistant, paintable complying with ASTM C 834 recommended for exposed applications on interior and protected exterior locations involving joint movement of not more than plus or minus 5 percent.

1. Available Products: Subject to compliance with requirements, products which may be incorporated in the Work include, but are not limited to the following:


a. "Chem-Calk 600," Bostic Construction Products Div.

b. "AC-20," Pecora Corp.

c. "Sonolac," Sonneborn Building Products Div.

d. "Tremco Acrylic Latex 834," Tremco, Inc.

E. Fire-Resistant Joint Sealers: Two-part, foamed-in-place, silicone sealant formulated for use in through-penetration fire-stopping around cables, conduit, pipes, and duct penetrations through fire-rated walls and floors. Sealants and accessories shall have fire-resistance ratings indicated, as established by testing identical assemblies in accordance with ASTM E 814, by Underwriters' Laboratories, Inc., or other testing and inspection agency acceptable to authorities having jurisdiction.

1. Available Products: Subject to compliance with requirements, products which may be incorporated in the Work include, but are not limited to, the following:


a. "Dow Corning Fire Stop Foam," Dow Corning Corp.

b. "Pensil 851," General Electric Co.

2.3 BEARINGS

A. Unless otherwise specified, all bearings shall be equal to Link Belt P300 ball bearings up to and including 1-11/16". Larger sizes to be Link Belt 6800 Series adaptor mounted and have split bearings.

B. All bearings to be mounted in a split journal. Equipment manufacturer to determine whether oil or grease lubrication is required.

C. Bearings to be doweled in place after 30 days of satisfactory running.

D. Bearings to be selected for 100,000 hours minimum life and 200,000 hours average life, based on motor horsepower with a factor of 2.0 in accordance with the design standards set forth in the Anti-Friction Bearing Manufacturers Association, Design (B-10), and the published rating data.


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E. Upon request, bearing loads calculations to be substantiated with submittal prints by attaching a copy of the fan manufacturer's computer run out.

2.4 DRIVES

A. Unless otherwise specified, all drives shall be selected for a minimum of 1.4 service factor based on motor brake horsepower and including unit factors for length of belt, effective sheave diameter and arc of contact correction.

1. In no case will any driver with a 10 H.P. motor or larger have less than two (2) belts, nor will any drive be furnished with an arc of contact of less than 160° at minimum effective sheave diameter.

2. Adjustable drives shall be provided for fans having motors of 10 H.P. or less. Sheaves shall be selected to operate at mid-point of the fan curve to allow for adjustment in both directions. Fans having motors larger than 10 H.P. shall be provided with fixed sheaves after systems are balanced.

3. It is the responsibility of the Trade to see that all fans deliver the design capacity at actual static pressures up to design static pressure. Fan sheaves shall be replaced as necessary to obtain desired results.

4. All sheaves to be dynamically and statically balanced and multiple belts shall be machine matched in sets.

5. Fan motors, shafts, pulleys and sheaves shall be provided with deep keyways and pulleys and sheaves shall be properly keyed and secured in place. The sheaves to shafts are not acceptable.

6. Each belt drive shall be provided a NSC and OSHA approved belt guard. Guards shall be constructed of No. 12 USS gauge, 3/4" diamond mesh wire screens, or equivalent, welded to 1" structural steel, 1/8" thick angle frames and shall enclose all belts and sheaves. Tops and bottoms to be of substantial sheet metal not less than No. 18 USS gauge.

a. Guard shall be secured to the driven machines or to foundations or floors by heavy structural angle supports and anchor bolts.

b. Braces or supports secured to motors will not be permitted and braces and/ or supports must not "bridge" the sound and vibration isolators.

c. Guards shall be removable for maintenance.

d. Lubrication fittings shall be extended to point that will permit lubrication without removing guards.

B. Guard shall be designed with adequate provision for movement of motor required to adjust belt tension.

Means shall be provided to permit lubrication, use of speed counters, and other maintenance and testing operations with belt guard in place.

C. For all direct drive equipment, provide a NSC and OSHA approved coupling guard of formed metal or heavy wire mesh securely bolted in place.

2.5 EQUIPMENT BASES

A. Concrete foundations ready to accept mechanical equipment will be provided under Division 3, Concrete. Furnish information concerning size and location of equipment requiring concrete foundations and pads.


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B. Furnish all anchor bolts and anchor bolt sleeves of adequate size and length to properly anchor all equipment to be installed. Anchor bolts will be set in concrete foundations or bases under Division 3, Concrete, under full supervision of the Trade Contractor who provides the respective equipment.

1. Furnish templates for the installation of concrete foundations and bases and for placement of anchor bolts and sleeves. Anchor bolts and sleeves will be installed under Division 3, Concrete.

2. Equipment bed plates shall be leveled and rigidly bolted in place and the bed plates, where installed shall be filled with EMBCO non-shrink grout by the trade who provides the respective equipment.

C. Housekeeping pads shall be minimum 4" unless otherwise indicated.

2.6 SPECIAL TOOLS

On completion of the work, the Contractor shall furnish and deliver to the Owner, any special tools that may be required for the proper servicing of any equipment furnished for the project.

2.7 PRE-FABRICATED ROOF CURBS

A. Prefabricated roof curbs to be of prime galvanized steel construction, 18 gauge or as required, meeting ASTM A446, A525, A526 & A527, with welded corners and 3" can’t fully mitered with seams joined by continuous welds.

B. Curbs to be internally reinforced, factory insulated with 1-1/2" thick 3# density insulation, and factory installed wood nailers fastened from underside with Tek screws.

C. Height to be 18" (or height as indicated on Drawings) above roof deck.

D. Top of all roof curbs shall be level, with pitch built into curb when deck slopes 1/4 of an inch per foot or greater.

E. Roof Curbs shall be as manufactured by ThyCurb Fabricating Division of ThyBar Corporation, Penn Ventilator Co. or Vent Products Co.

F. Where noted on the Drawings, prefabricated roof curbs are to be provided by the equipment suppliers with curbs matched to the equipment.

Roof curbs which are not provided by equipment suppliers must be provided by Contractor.

PART 3 EXECUTION

3.1 EXAMINATION

A. Examine substrates, areas, and conditions, with Installer present, for compliance with requirements for installation tolerances and other conditions affecting installation and application of joint sealers and access panels.

B. Do not proceed with installation until unsatisfactory conditions have been corrected.

3.2 PREPARATION FOR JOINT SEALERS

A. Surface Cleaning for Joint Sealers: Clean surfaces of joints immediately before applying joint sealers to comply with recommendations of joint sealer manufacturer.

B. Apply joint sealer primer to substrates as recommended by joint sealer manufacturer. Protect adjacent areas from spillage and migration of primers, using masking tape. Remove tape immediately after tooling without disturbing joint seal.


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3.3 ERECTION OF METAL SUPPORTS AND ANCHORAGE

A. Cut, fit, and place miscellaneous metal fabrications accurately in location, alignment, and elevation to support and anchor mechanical materials and equipment.

B. Field Welding: Comply with AWS "Structural Welding Code."

3.4 APPLICATION OF JOINT SEALERS

A. General: Comply with joint sealer manufacturers' printed application instructions applicable to products and applications indicated, except where more stringent requirements apply.

1. Comply with recommendations of ASTM C 962 for use of elastomeric joint sealants.

2. Comply with recommendations of ASTM C 790 for use of acrylic-emulsion joint sealants.

B. Tooling:

Immediately after sealant application and prior to time shinning or curing begins, tool sealants to form smooth, uniform beads; to eliminate air pockets; and to ensure contact and adhesion of sealant with sides of joint. Remove excess sealants from surfaces adjacent to joint. Do not use tooling agents that discolor sealants or adjacent surfaces or are not approved by sealant manufacturer.

C. Installation of Fire-Stopping Sealant:

Install sealant, including forming, packing, and other accessory materials, to fill openings around mechanical services penetrating floors and walls, to provide fire-stops with fire-resistance ratings indicated for floor or wall assembly in which penetration occurs. Comply with installation requirements established by testing and inspecting agency.

3.5 CLEANING

A. Coordinate general cleanup with the work as specified in Division 1.

B. Equipment:

Clean in conjunction with and in the same manner as the connected piping system.

C. Ductwork:

1. Remove debris and trash from ductwork.

2. Run supply and exhaust fans before grilles and registers are installed and before ceilings and walls are painted.

3. Room surfaces soiled from construction dust in ductwork to be cleaned or repainted at no additional cost to the Owner.

3.6 OPENINGS

A. Where temporary openings are necessary thru walls and partitions of the building for the entry or installation of tanks, fans, or other machinery or apparatus, or for driveways and other facilities, the permanent work of the mechanical trades at said openings shall be temporarily omitted and installed after equipment is brought into the building or after temporary facilities are removed.


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B. Refer to other Sections of the Specifications for framing of openings for ducts, grilles, registers, etc., in walls, partitions, floors, roofs, etc.

The trade for each service shall be responsible for locating and providing the proper dimensions for all required openings.

Space between ducts and wall for floor openings shall be sealed with Dow Corning Fire Stop Foam or Dow Corning Fire Stop Sealant per manufacturer's installation instructions.

C. Contractor shall notify the Engineer if any existing openings are uncovered adjacent to location of a new opening.

The new opening shall not be drilled if the existing can be used unless directed by the Engineer.

3.7 PAINTING

GENERAL REQUIREMENT: Refer to individual Sections in Division 15 mechanical specifications for itemized scope of painting work.

A. Prime Coat:

1. Shop-fabricated and factory-built equipment not primed, galvanized, or protected by plating shall be cleaned and given one shop coat of zinc-chromate primer before delivery to the site.

2. Any portions of the shop coat damaged in delivery or during construction shall be recoated.

3. Do not paint nameplates, labels, tags, sprinkler heads, stainless steel, or chromium-plated items such as valve stems, motor shafts, levers, handles, trim strips, and like items.

B. Finish Coat:

1. Piping, ductwork, and equipment shall be left cleaned and primed, ready for finish painting.

2. Finish painting shall be provided as specified in Section 09928.

3. Ductwork behind grilles, registers, diffusers, and other like items, which is exposed to view shall be given one coat of primer and one finish coat of paint.

3.8 PREFABRICATED ROOF CURBS

Install in accordance with manufacturer's instructions and recommendations.

END OF SECTION


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ERECTING AND JOINTING INTERIOR PLANT PROCESS PIPING 15030-1

SECTION 15030

ERECTING AND JOINTING INTERIOR PLANT PROCESS PIPING

PART 1 GENERAL


A. All interior plant piping, fittings, and appurtenances.

B. The Work includes, but is not limited to, the following:

1. All types of piping including process, plumbing and compressed air, except where specified under other Sections.

2. Piping embedded in concrete within a structure or foundation.

3. Work on existing exposed pipelines.

4. Installation of valves, gates and specials shown or specified.

5. All joints, specials, couplings, flexible couplings, mechanical couplings, harnessed and flanged adapters, expansion couplings, sleeves, tie rods, jointing and gasketing materials and all other Work required to complete the piping installation.

6. Regarding Testing of Piping, refer to Section 15032 - Testing Piping Systems.

7. Regarding Supporting of Piping, refer for Pipe Supports, Hangers, Restraints, thrust blocks and kickers to Section 15140 - Supports & Anchors.

C. Piping materials, coatings and linings shall be as specified or shown on the Drawings.

D. Coordination: Review installation procedures under other Sections and coordinate with the Work which is related to this Section.


A. Section 09928 – Protective Coating System.

B. Section 15020 - Plant Process and Yard Piping.

C. Section 15032 - Testing Piping Systems

D. Section 15140 - Supports and Anchors.

E. Section 15410 - Plumbing and Compressed Air Piping.

1.3 SUBMITTALS

A. Submit shop drawings and product data under provisions of Section 15010.

B. Submit shop drawings indicating dimensions, layout of piping, elevations, intersections, connections, support systems, valves, specials, accessories, equipment, etc.

C. Tests:

1. Submit description of proposed testing methods, procedures and apparatus.

2. Submit test reports for each system.

D. Record Drawings:

1. During progress of the Work keep an up-to-date set of drawings showing field and shop drawing modifications.


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2. Submit within thirty (30) calendar days of Contract completion mylar tracings and two paper prints showing the actual in-place installation of all piping installed under this Section on 24" x 36" drawings. Show all piping in plan and in section with reference dimensions and elevations required for complete record drawings of the piping system.


A. Requirements of Regulatory Agencies:

1. Comply with applicable requirements of UL and other jurisdictional authorities.

2. Building Codes: Comply with applicable requirements of all governing authorities.

3. Permits: Contractor shall obtain and pay for all required permits, fees and inspections by authorities having jurisdiction.

B. Reference Standards:

Comply with the latest edition of the following:

1. ANSI B13.3 - Code for Pressure Piping

2. AWS D1.1 - Structural Welding Code

3. AWS D10.4 - Welding of Austenitic Chromium-Nickel Steel Piping and Tubin

4. AWS D10.7 - Gas Shielded-Arc Welding of Aluminum and Aluminum Alloy Pipe

5. AWS D10.9 - Standard for Qualification of Welding Procedures & Welders for Piping & Tubing

6. AWWA C206-Field Welding of Steel Water Pipe Joints

7. AWWA M11 - Steel Pipe Design and Installation

8. NEPA No. 26, Supervision of Valves Controlling Water Supplies for Fire Protection.

PART 2 PRODUCTS

2.1 MATERIALS

As defined in the applicable Sections of these Specifications.

PART 3 EXECUTION

3.1 TRANSPORTATION AND DELIVERY

A. Precautions shall be taken to prevent pipe damage during transportation and delivery to the site.

Pipe shall not be dropped or moved in any way to cause damage to pipe, lining or coating.

When handling pipe, a suitable pipe hook or sling around the pipe shall be used.

Pipe shall not be lifted by passing sling through pipe or by using hooks on pipe ends.

B. Any pipe damaged in the process of transportation, handling or installing shall be replaced and/or repaired by contractor at no additional cast to Owner.


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3.2 PIPING INSTALLATION GENERAL

A. The dimensions shown on the Drawings for the location of pipelines have been established with the intent that there will be no interferences.

Contractor shall check all dimensions shown on the Contract Drawings prior to the installation of Work and shall notify the Engineer promptly of any interferences or errors discovered. If interferences are found to exist prior to or during construction, changes in the location of pipelines to avoid such interferences shall be made at no extra cost to the Owner and in a manner as reviewed by the Engineer.

B. Elevations and dimensions locating pipelines are shown on the Drawings to the centerlines of the pipe unless otherwise indicated.

C. Piping connections and dimensions to equipment are subject to changes to suit the types of equipment furnished.

D. Piping suspended from ceilings shall be installed to provide maximum head room consistent with good installation.

E. The layout of the piping and fittings shall be carefully checked to determine that the related equipment can be properly assembled to produce a workable arrangement.

Defective or improperly fabricated Work shall be rejected and replaced with Work which, when completely assembled, shall result in an arrangement which shall function as intended and as shown on the Drawings.

F. All pipelines shall be straight and true in alignment, grade and location indicated, designated or required, and all installation shall be made in a workmanlike manner to the satisfaction of the Engineer.

Pipe and fittings shall be adequately braced and blocked or tied, hung or supported for satisfactory installation.

G. As soon as pipes are in place, all open ends shall be capped until permanent connections are made.

All pipelines shall be securely supported when required either by hanging from beams with suitable pipe hangers or supported on walls by suitable wall brackets.

Where it is necessary, install hangers or supports after concrete is poured or other masonry Work finished.

Anchor bolts with expansion shields shall be used.

H. Where pipes pass through masonry walls, floors and partitions, the juncture shall be made as shown on the Drawings.

Where no details are shown, Contractor shall either rough in the piping before the concrete is poured or the masonry completed, or shall provide suitable plugs, sleeves or forms for piping.

After the pipes have been installed, the openings shall be filled solid; suitable allowance being made, however, for the expansion and contraction of the piping.

The cutting of concrete for pipe shall be avoided wherever possible, and in no case where such cutting is necessary shall reinforcing rods be cut or disturbed, and no such cutting shall be done without the permission of the Engineer.

All openings made for pipe Work shall be neatly patched in a workmanlike manner.

I. Horizontal runs shall be given as steep a pitch with even grade toward the outlet as conditions will permit, and care shall be taken in laying out piping that there is no interference with the proper location of piping for other purposes or other equipment.


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No change shall be made in the general location shown for piping, or in the method of running and connecting same, except with the written approval of the Engineer.

When any change is made, a record of the location of all pipes so changed shall be kept by Contractor and a copy of such record shall be given to the Engineer showing the location of all piping.

J. Install dielectric fitting between dissimilar pipe materials as required.

3.3 PROTECTION OF PIPING SYSTEM

A. Install and maintain pipe and equipment which is clean and free from rust, dirt, scale, etc.

B. No piping shall be placed when wet, nor shall any free moisture be present inside any air piping during installation.

3.4 PIPE SUPPORTS AND HANGERS

Pipe supports and hangers shall be in accordance with Section 15140.

3.5 WELDING

A. All welding of piping and/or special fittings shall be done in conformity with the current ANSI B31.1, "Pressure Piping".

A certification of the welder's qualifications, in conformity with the requirements of this code, shall be submitted to the Engineer.

B. Tee connections in welded piping shall be made with a factory fabricated butt welding tee or with weld-o-let of butt, socket or threaded type. When weld-o-lets are used, the branch connection shall be one-half the diameter of the main or less.

3.6 FLANGED JOINTS

A. All flanged joints shall be made temporarily with gaskets in place using a minimum number of bolts to support the piping. Any misalignment of the assembled piping shall be adjusted or corrected in a manner approved by the Engineer.

B. Any misaligned flanges shall be machined to fit, or approved spacer pieces and gaskets shall be installed if necessary.

The temporary assembly of the flanged piping shall demonstrate that there will be no undue stresses in the piping or at the connections to the equipment. The temporary assembly shall be approved by the Engineer before the joints are tightened.

Flanged joints shall then be completed and made watertight and the tension in the flange bolts, when tightened, shall not exceed 18,000 psi at the minor diameter of the bolt threads.

3.7 INSTALLATION OF COPPER TUBING

A. Interior or Exposed Copper Tubing

Copper tubing with solder joint connections shall have all burrs removed from the tubing before joints are made.

Both the inside of the fittings and the outside of the tubing shall be cleaned and a flux shall be evenly distributed across the joining surfaces.

Joints shall be made by applying heat and solder to the end of the fitting until the solder melts and then passing the flame toward the center of the fitting until the solder is absorbed and appears uniformly around the end of the fitting.

Excess solder shall be removed while the solder is still in a plastic state.

All joints shall be allowed to cool at room temperature.


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3.8 SLEEVE TYPE COUPLINGS

For sleeve type couplings, diametrically opposite bolts shall be equally tightened on the connection so that the gaskets will be brought up evenly all around the pipe. Final tightening shall be done with torque wrenches set for the torque recommended by the coupling manufacturer.

3.9 PIPING MARKERS

Refer to Section 15190 – Mechanical Identification.

3.10 TESTING

A. Where applicable, pipes shall be flushed clean and tested and any leaks shall be made tight.

B. Tests shall be conducted as specified under Section 15032 – Testing Piping Systems.

3.11 PAINTING

Piping, fittings and appurtenances shall be painted in accordance with Section 09928 – Protective Coating Systems.

3.12 SUPPORTS FOR PRESENT PIPING

Wherever Contractor is required to expose, suspend or reroute present piping, supports for such piping shall be provided as is required for new piping in accordance with paragraph 3.04 Pipe Supports and Hangers, this Section.

3.13 WRECKING AND REPAIR

A. The Contractor shall do its own excavation for piping as required to complete the Work. If excavation is required below present concrete slabs, the backfill materials shall be sand flushed in place or class B concrete fill as required by the Engineer. The concrete used to repair the structure shall be Class A concrete. Where reinforcing is cut, dowels shall be used for laps. Junctures between the present portions of slabs remaining and new slabs shall be uniformly saw cut.

B. All such repair procedures shall be subject to review by the Engineer.

END OF SECTION


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BLANK PAGE


WATER PLANTS

TESTING PIPING SYSTEMS 15032-1

SECTION 15032

TESTING PIPING SYSTEMS

PART 1 GENERAL


A. Testing of all plant piping, as specified.

B. Pipelines to be Tested:

1. Pump Suction and Discharge piping

2. Plant yard piping

3. Service Water piping

4. Chlorine solution piping

5. All other new piping not specifically listed above.


A. Section 02675 – Cleaning and Disinfection of Water Piping, Equipment and Facilities

B. Section 15105 – Pipe and Pipe Fittings

C. Section 15106 – Ductile Iron Pipe and Fittings.

D. Section 15410 – Plumbing


All equipment, devices, and tools required for testing of piping systems shall be provided by Contractor and shall be of first class construction designed to perform the required service.

PART 2 PRODUCTS

2.1 TESTING EQUIPMENT

A. All testing equipment, including meter or measuring facilities shall be furnished by Contractor, and shall be subject to the Owner's approval.

B. Water for testing of each pipeline will be provided by Owner.

PART 3 EXECUTION

3.1 GENERAL

A. Test all piping as specified herein except as otherwise authorized by the Engineer.

B. Notify the Engineer 48 hours in advance of testing.

C. Provide all testing apparatus, including pumps, hoses, gages and fittings.

D. Pipelines shall hold the specified test pressure for a period of one (1) hour.

E. Repair and retest pipelines which fail to hold specified test pressure or which exceed the allowable leakage rate.

F. Conduct all tests in the presence of the Engineer unless otherwise approved.

G. Contractor shall perform all specified testing.


WATER PLANTS

TESTING PIPING SYSTEMS 15032-2

3.2 PRESSURE AND LEAKAGE TESTS PROCEDURES

A. Exposed and Interior Piping - PRESSURE & LEAKAGE TEST

1. Ensure that all supports and restraints and piping protection are securely in place.

2. Section to be tested shall be slowly filled with water to allow for escape of entrapped air. Install corporation cocks as necessary for removal of air.

3. Test only 1 pipe section at a time.

4. Apply test pressure for one (1) hour and observe pressure gage. Carefully check for leaks while test pressure is being maintained.

a. Examine exposed pipe, joints, fittings and valves. Stop visible leakage or replace the defective pipe, fitting or valve.

b. Pump water into the line with the test pump to maintain the specified test pressure for a one-hour period.

c. All repair, replacement, and retesting required because of failure to meet test requirements shall be made by Contractor.

5. Allowable Leakage Rates: No leakage permitted.

6. Leakage Test shall be repeated following corrective work until a satisfactory test is achieved.

3.3 PIPE TESTING SCHEDULE

Test Pressure Service Material (Psi)

Plant Yard Piping DIP 150

Pump Suction and Discharge Piping DIP 150

All other piping not specifically listed above shall be tested at 1.5 times operating pressure.

3.4 CLEANING

A. Piping 24 inches in diameter and larger shall be inspected from the pipe interior and all debris, dirt and foreign matter removed.

B. All piping shall be thoroughly cleaned and flushed in a manner approved by Engineer prior to being placed into service.

END OF SECTION


WATER PLANTS

BUTTERFLY VALVES 3-INCH THROUGH 72-INCH 15040-1

SECTION 15040

BUTTERFLY VALVES 3-INCH THROUGH 72-INCH

PART 1 GENERAL

1.1 SPECIFICATION INCLUDES

A. All butterfly valves and accessories for buried, exposed, submerged and other types of piping for transmission, plant process and yard piping and interior plant process piping except where included in other Sections.

B. Coordination: Review installation procedures under other Sections and coordinate with the Work which is related to this Section, including buried piping installation, exposed piping installation, plumbing, air compressed piping, instrumentation piping, etc.


A. Section 01330 – Submittal Procedures

B. Section 01600 – Materials and Equipment

C. Section 01655 – Starting of Systems

D. Section 01800 – Operation and Maintenance Data

E. Section 09928 – Protective Coating Systems

F. Section 15010 – Basic Mechanical Requirements

G. Section 15030 – Erecting & Jointing Interior Process Piping

H. Section 15106 – Ductile Iron Pipe and Fittings

1.3 REFERENCES

A. ANSI B16.1 - Cast Iron Pipe Flanges and Flanged Fittings.

B. ASTM A36 - Standard Specification for Carbon Structural Steel

C. ASTM A48 - Gray Iron Castings.

D. ASTM A126 - Gray Iron Castings for Valves, Flanges and Pipe Fittings.

E. ASTM A240 - Heat-Resisting Chromium and Chromium Nickel Stainless Steel Plate.

F. ASTM A276 - Stainless Steel Bars and Shapes.

G. ASTM A320 - Alloy Steel Bolting Materials for Low Temperature Service.

H. ASTM A395 - Standard Specification for Ferritic Ductile Iron Pressure Retaining Castings.

I. ASTM A536 - Ductile Iron Castings.

J. ASTM A564 – Standard Specification for Hot-Rolled and Cold-Finished Age-Hardening Stainless Steel Bars and Shapes.

K. ASTM A743 – Standard Specification for Castings, Iron-Chromium, Iron-Chromium-Nickel, Corrosion Resistant, for General Applications.

L. AWWA C111 - Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings.


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M. AWWA C115 – Standard for Flanged Ductile-Iron Pipe with Ductile-Iron or Gray Iron Threaded Flanges.

N. AWWA C207 - Steel Pipe Flanges for Waterworks Service – Sizes 4 In. Through 144 In.

O. AWWA C504 - Rubber-Seated Butterfly Valves, 3 In. Through 72 In.

P. AWWA C541 – Hydraulic and Pneumatic Cylinder and Vane-Type Actuators for Valves and Slide Gates.

Q. AWWA C542 - Electric Motor Actuators for Valves and Slide Gates.

R. AWWA C550 - Protective Interior Coatings for Valves and Hydrants.

S. AWWA C606 - Grooved and Shouldered Joints.

T. AWWA Manual M49 - Butterfly Valves: Torque, Head Loss and Cavitation Analysis

1.4 QUALITY ASSURANCE - Manufacturer's Qualifications:

A. Valves and appurtenances provided under this Specification shall be the standard product in regular production by manufacturers whose products have proven reliable in similar service for at least five (5) years.

B. Insofar as possible all valves of the same specific type shall be the product of one (1) manufacturer.

1.5 SUBMITTALS

Submit shop drawings and product data under the following requirements:

A. Identify variations from this specification and product or system limitations that may be detrimental to successful performance of the completed work.

B. Apply signed stamp certifying that review, verification of product requirements, field dimensions, adjacent construction work, and coordination of information is in accordance with the requirements of the work.

C. Provide space for review stamp.

D. Revise and resubmit submittals as required, identifying all changes made since previous submittal.

E. Distribute copies of reviewed submittals to concerned parties. Instruct parties to promptly report any inability to comply with provisions.

F. Valve Manufacturer Submittals: Submit for review detailed drawings, data and descriptive literature on all valves and appurtenances, including:

1. Dimensions.

2. Size.

3. Materials of construction.

4. Weight.

5. Protective coating.

6. Actuator weight.

7. Calculations for actuator torque where applicable.


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8. Actuators.

9. Number of turns from closed to full open.

G. Manufacturer's Certifications: Submit manufacturer's certificates of compliance with ANSI, AWWA and other Standards listed herein.

H. Submittals which do not conform to the requirements of this Specification will be returned without review.

1.6 OPERATION AND MAINTENANCE DATA

A. Submit operation and maintenance data under provisions of Section 01800.

B. Include installation instruction, assembly views, lubrication instructions, and replacement parts list.

C. Submit a detailed operation and maintenance manual for all valves and appurtenances provided under this Section, including the following information:

1. Product name and number.

2. Name, address and telephone number of manufacturer and local distributor.

3. Instruction bulletins for operation, maintenance and recalibration.

4. Complete parts and recommended spare parts lists.


A. Deliver products to site under provisions of Section 01600.

B. Store and protect products under provisions of Section 01600.

C. Valves and appurtenances which are cracked, chipped, distorted or otherwise damaged or dropped will not be accepted.

D. Store all valves and appurtenances off the ground in enclosed shelter.

PART 2 PRODUCTS

2.1 GENERAL

A. Valves shall be installed as shown on the Contract Drawings and as otherwise necessary to provide a safe, convenient, flexible and economical control of all piping systems and their related equipment.

B. Valves 4" and larger equipped with flanged joints shall be in conformance with the current ANSI B16.1, "Cast Iron Pipe Flanges and Flanged Fittings", Class 125 drilling. Valves with steel flanges shall comply with AWWA C207, Class D.

C. Valves 4" and larger equipped with mechanical joints shall be in conformance with AWWA C111, "Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings".

D. Valves 4" and larger equipped with grooved joints shall be in conformity with AWWA C606, “Grooved and Shouldered Joints".


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2.2 BUTTERFLY VALVES (FOR WATER SERVICE, C504, 3-inch through 72-inch)

A. Butterfly Valves furnished under this section shall be of the tight-closing, rubber-seat type conforming to the American Water Works Association Standard C504, latest edition.

B. Valves shall be designed for buried exposed or submerged service with potable or raw water and shall comply with the whole of the AWWA C504 Standard, except as specified under these specifications and the options, stipulations or modifications as indicated.

The references as listed hereafter have the same numerical designation as shown in AWWA C504, of the Forward Section III.A.

1. Standard to be used: AWWA C504 Standard for Rubber-Seated Butterfly Valves, latest edition.

2. Compliance with NSF 61 is required for all parts in contact with finished water.

3. Size of Valve: As indicated on the Drawings or in the bidding documents.

4. Quantity required: As indicated in the contract documents.

5. Type of body: Flanged short body unless shown differently on the drawings and/or as specified elsewhere in these specifications.

6. Minimum valve classification shall be Class 150B.

7. Maximum non-shock shutoff pressure and maximum non-shock line pressure is 150 psi.

8. Flow through valve:

a. Under normal conditions - < 6 FPS

b. Maximum flow condition - 16 FPS

9. Connecting piping – Flat faced flanges matching ANSI B16.1 Class 125 drilling and sizes as indicated on the drawings.

10. The following information is required from the valve manufacturer:

a. Valve port diameter

b. Clearances for the valve and actuator for both service and removal.

c. Number of turns from open to close and reverse for manual actuators.

d. Assembled weight of the valve, actuator and bonnet extension. Individual weights of valve and actuator are also required.

e. Valve torque calculation.

f. Cavitation coefficients.

g. Preferred flow direction.

h. Valve and actuator component materials.

i. Detailed dimensions.

j. Actuator manufacturer, model and torque capacity.

k. Interior and exterior coating materials.


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l. Clearance for valve disc for full operation.

m. Disc position verses flow coefficient, Cv, curve.

11. Materials:

a. Valve Bodies: Gray iron conforming to ASTM A126, Class B or ductile iron conforming to ASTM A536, Grade 65-45-12.

b. Valve Shafts: Valve shafts shall be turned round and polished and shall be constructed of Type 304 or Type 316 stainless steel. The shaft shall be connected to the disc by means of solid, smooth stainless steel taper or dowel pins. Pins shall be made from stainless steel materials that will not gall to the shaft.

c. Valve Discs: Ductile iron conforming to ASTM A536, Grade 65-45-12.

d. Valve Seats: Valve seats shall be EPDM or Buna-N and shall be either on the body or on the disc and be mechanically retained to the body or the disc with stainless steel retainer segments and bolts. Seat shall be easily replaced or adjusted in the field with normal hand tools. Epoxy injected seats are not allowed.

Seating surfaces shall be stainless steel and designed for frequent operation without damage to seats or mating surfaces.

e. Protective Coating: Interior and exterior surfaces shall be shop coated with a fusion bonded epoxy coating (minimum 16 mils DFT) in accordance with AWWA C550.

f. Valve and Actuator Exterior Bolts: All exterior bolts, (not including flange bolts), nuts and washers shall be Type 316 stainless steel.

g. Interior Fasteners: All valve interior fasteners shall be Type 316 stainless steel.

12. Type of installation: Valves shall be for buried or submerged service.

13. Actuator type and service conditions:

a. Type: All valves shall be provided with manual actuators.

b. Service: Open/Close.

14. Manual Actuators:

a. Actuators shall be designed, manufactured and tested in accordance with AWWA Standards C504 and C516.

b. Valve actuators shall be sized based on pipeline velocity of 12 feet per second and unidirectional service.

c. Manual actuators shall be worm-gear or traveling nut type with a 2” AWWA square nut, suitable for buried and submerged service.

d. Actuator shall be equipped with adjustable mechanical stops limiting valve disc travel in the open and close directions.


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e. The actuator housing shall be fully sealed and constructed of ASTM A48 Class 40 gray iron or ASTM A536 Grade 65-45-12 ductile iron. All fasteners shall be stainless steel, Type 316.

f. Actuator housings shall be fully sealed; 90% grease packed and designed to withstand 23 feet of water submersion or to the depth as indicated on the drawings, whichever is greater.

g. Actuators shall have a minimum safety factor of 1.5 of the actuator rated torque capacity to the maximum torque required by the valve.

h. Actuators shall be capable of withstanding 450 foot-pounds of torque against the stops without damage to any parts of the actuator or valve.

i. Provide sealed bonnet/stem extensions on direct bury installations where actuators are placed in a manhole or vault. Sealed bonnets/stem extensions shall be a minimum of 48” in length or as indicated on the drawings.

j. The number of turns of the 2” square nut required from full open to close position and reverse shall be 150 to 300 for 48” valves.

k. Actuator housing shall be coated with an epoxy conforming to AWWA C550 with a minimum dry film thickness of 8 mils.

l. Worm-gear actuators shall be as manufactured by EIM or Limitorque. Substitutions not allowed.

m. Actuators shall be mounted and installed by the valve manufacturer.

n. Valves shall turn counterclockwise, or to left, to open.

15. Cylinder Actuators: As specified elsewhere, if required.

16. Electric Actuators: As specified elsewhere, if required.

17. Valve and Actuator Arrangement and Position: As shown on the contract drawings.

18. Affidavit of compliance with AWWA C541 or C542 not required unless specified elsewhere.

19. Flow coefficient, Cv, shall be calculated per AWWA Manual M49.

20. Valve disc position versus flow coefficient curve is required.

21. Shop Inspection:

The owner reserves the right to examine the valve manufacturing and/or assembly facilities at any time during normal business hours with a minimum of 72 hours notice.

22. Maximum total pressure during transient condition is 250 psi. There shall not be any structural failure and/or visible deformation in the valve body, disc, shaft or end plates. There shall be no leakage through the joints and/or shaft seals.

23. Water Temperature: 33°F to 80°F

24. Leakage test in both directions is required with supplied actuator attached.


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25. Provide maximum headloss data for each size and class of valve.

26. An outline of piping arrangement sufficient to describe turbulent conditions impact the valve disc is required.

27. Anticipated Excessive Chemical Exposure:

Chlorine will be applied to the piping system for disinfection purposes. Chlorine will be applied in concentrations from 25 to 100 mg/l for periods ranging from 1 to 24 hours during the disinfection period. The cycle may be repeated several times until testing indicates the absence of coliform bacteria.

28. Flat faced flanges are specified.

29. The Owner reserves the right to witness shop testing of any or all valves at the manufacturer’s facility. The manufacturer shall give the Owner 21 days notice prior to date of testing and testing duration to allow for travel scheduling. The valves/actuator assembly shall be pre-tested by the manufacturer prior to the arrival of the Owner. If the valve(s) fails the Owner witnessed test, the manufacturer shall reimburse the Owner for all costs associated with the failed test.

30. No change.

31. Test records as included in AWWA C504 shall be provided.

32. Non-standard End Connections: Not used.

33. Valve(s) will not be operated more than once per month.

34. Stuffing box not required

35. Shaft Seals: Self compensating V-type packing. Petroleum based products are not present at the site.

36. Electric Actuator: As specified elsewhere, if required.

37. Protective Coatings per AWWA C550 and holiday testing is not required.

38. The valve manufacturer shall provide a signed affidavit of compliance that the provisions of AWWA C504 and C550 have been met.


A. M&H Valve Company

B. Val-Matic

C. DeZurik

D. Crispin

E. Olsen Technologies, Mosser Valve

F. Milliken


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PART 3 EXECUTION

3.1 INSTALLATION

A. Install valves and specialties in accordance with manufacturer's recommendations and instructions to permit intended performance.

B. The manufacturer or supplier of valves and specialties shall furnish a qualified field engineer for whatever period of time may be necessary to assist and direct the Contractor in the proper installation of the equipment furnished, to observe and check initial performance, and whose duty shall include the instruction of the plant operating personnel in the proper operating and maintenance procedures.

C. Extreme care shall be used in the handling, storage and installation of equipment to prevent damage or distortion of the equipment and to ensure proper performance.

3.2 PAINTING

A. Valves and specialties shall be painted in accordance with applicable AWWA standard specified and with Section 09928 of these Specifications.

3.3 TESTING

A. All valves shall be given hydrostatic shop pressure test in accordance with applicable AWWA standard specified. The valves shall be tested, first by applying the hydrostatic pressure with the valve open, and then with the valve closed. The valves shall be tight and secure under the test pressure.

B. Hydrostatic testing to conform to AWWA C504 except as modified below:

1. Install actuator prior to hydrostatic testing. Test actuator to verify actual number of turns match manufacturer's published number of turns. Verify valve stops are in correct positions.

2. Open and close valve prior to performing shell test and prior to each leakage test.

3. When tested with water, adequately dry seat and disc.

4. Pressure Gauges: Calibrated within past 12 months; 0-500 psi range in increments of 5 psi; present calibration certificates prior to hydrostatic testing.

5. During shop testing, the valve shall be operated two times prior to each leakage test. Each valve shall be leakage tested at 150 psi in both directions. The disc shall be operated two times between each leakage test. If the valve leaks, the seat shall be adjusted, operated two times and leakage tested again until there is no leakage in either direction and no adjustments to the seat.

6. 300 ft-lbs of torque shall be applied to the operating nut at the full closed and full opened positions without failure to demonstrate compliance these specifications.

END OF SECTION


WATER PLANTS

GATE VALVES 15043-1

SECTION 15043

GATE VALVES

PART 1 GENERAL 1.1 SECTION INCLUDES

A. Gate valves.

B. Knife Gate Valves.

1.2 REFERENCES

A. ASTM A 307 - Standard Specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile.

B. ASTM B 62 - Standard Specification for Composition Bronze or Ounce Metal Casting.

C. ASTM D 429 - Standard Test Methods for Rubber Property-Adhesion to Rigid Substrates.

D. ASTM B 763 - Standard Specification for Copper Alloy Sand Casting for Valve Application.

E. AWWA C 500 - Standard for Metal-Seated Gate Valves for Water Supply Service.

F. AWWA C 509 - Standard for Resilient-Seated Gate Valves for Water Supply Service.

G. AWWA C 515- Standard for Reduced Wall, Resilient- Seated Gate Valves for Water Supply Service.

H. AWWA C 550 - Standard for Protective Epoxy Interior Coatings for Valves and Hydrants.

1.3 SUBMITTALS


B. Submit manufacturer's product data for proposed valves for approval.

C. Provide detailed drawings of gearing mechanism for 20-inch and larger gate valves.

1.4 QUALITY CONTROL

A. Submit manufacturer's affidavit that gate valves are manufactured in the United States and conform to stated requirements of AWWA C 500, AWWA C 509, AWWA C 515, and this Section, and that they have been satisfactorily tested in the United States in accordance with AWWA C 500, AWWA C 509, and AWWA C 515.


WATER PLANTS

GATE VALVES 15043-2

PART 2 PRODUCTS 2.1 MATERIALS

A. Gate Valves: AWWA C 500, AWWA C 509, AWWA C 515 and additional requirements of this Section. Valves to open counterclockwise.

B. If type of valve is not indicated on Drawings, use gate valves as line valves for sizes 20-inches and smaller. When type of valve is indicated, no substitute is allowed.

C. Gate Valves 1-1/2 inches in Diameter and Smaller: 125 psig; bronze; rising-stem; single- wedge; disc type; screwed ends

D. Coatings for Gate Valves 2 inches and larger: AWWA C 550 non-toxic, imparts no taste to water, functions as physical, chemical, and electrical barrier between base metal and surroundings, minimum 8-mil-thick, fusion-bonded epoxy. Prior to assembly of valve, apply protective coating to interior and exterior surfaces of body.

E. Gate Valves 2 inches in diameter: Iron body, double disc or resilient-seated, non-rising stem, 150-pound test, 2-inch square nut operating clockwise to close.

F. Gate Valves 3 inches to 12 inches in diameter: Non-directional, standard-wall resilient seated (AWWA C 509), parallel seat double disc (AWWA C 500), or reduced-wall resilient seated gate valves (AWWA C 515), 200 psig pressure rating, bronze mounting, push-on bell ends with rubber joint rings, and nut-operated unless otherwise specified. Provide approved standard-wall resilient seated valves. Provide approved reduced-wall resilient seated valves.

Provide approved double disc valves. Comply with following requirements unless otherwise specified in Drawings:

1. Design: Fully encapsulated rubber wedge or rubber seat ring mechanically attached with minimum 304 stainless-steel fasteners or screws; threaded connection isolated from water by compressed rubber around opening.

2. Body: Cast or ductile iron, flange bonnet and stuffing box together with ASTM A 307 Grade B bolts. Manufacturer's initials, pressure rating, and year manufactured shall be cast in body.

3. Bronze: Valve components in waterway to contain not more than 15 percent zinc and not more than 2 percent aluminum.

4. Stems: ASTM B 763 bronze, alloy number-995 minimum yield strength of 40,000 psi; minimum elongation in 2-inches of 12 percent, non-rising.

5. O-rings: For AWWA C 500, Section 3.12.2. For AWWA C 509, Sections 2.2.6 and 4.8.2. For AWWA C 515, Section 4.2.2.5.

6. Stem Seals Consist of three O-rings, two above and one below thrust collar with antifriction washer located above thrust collar for operating torque.


WATER PLANTS

GATE VALVES 15043-3

7. Stem Nut: Independent or integrally cast of ASTM B 62 bronze.

8. Resilient Wedge: Molded, synthetic rubber, vulcanized and bonded to cast or ductile iron wedge or attached with 304 stainless steel screws tested to meet or exceed ASTM D 429 Method B; seat against epoxy-coated surface in valve body.

9. Bolts: AWWA C 500 Section 3.4, AWWA C 509 Section 4.4 or AWWA C 515 Section 4.4.4; stainless steel; cadmium plated, or zinc coated.

G. Gate valves 14 inch and larger in Diameter: AWWA C 500; parallel seat double disc gate valves; push-on bell ends with rubber rings and nut-operated unless otherwise specified. Provide approved double disc valves with 150 psig pressure rating. Comply with following requirements unless otherwise specified on Drawings:

1. Body: Cast iron or ductile iron; flange together bonnet and stuffing box with ASTM A 307 Grade B bolts. Cast following into valve body manufacturer's initials, pressure rating, and year manufactured. When horizontally mounted, equip valves greater in diameter than 12 inches with rollers, tracks, and scrapers.

2. O rings: For AWWA C 500, Section 3.12.2. For AWWA C 515, Section 4.2.2.5.

3. Stems: ASTM B 763 bronze, alloy number-995 minimum yield strength of 40,000 psi; minimum elongation in 2-inches of 12 percent, non-rising.

4. Stem Nut: Machined from ASTM B 62 bronze rod with integral forged thrust collar machined to size; non-rising.

5. Stem Seals: Consist of three O-rings, two above and one below thrust collar with antifriction washer located above thrust collar for operating torque.

6. Bolts: AWWA C 500 Section 3.4 or AWWA C 515 Section 4.4.4; stainless steel; cadmium plated, or zinc coated.

7. Discs: Cast iron with bronze disc rings securely penned into machined dovetailed grooves.

8. Wedging Device: Solid bronze or cast-iron, bronze-mounted wedges. Thin plates or shapes integrally cast into cast-iron surfaces are acceptable. Other moving surfaces integral to wedging action shall be bronze monel or nickel alloy-to-iron.

9. Provide bypass for double-disc valves (AWWA C500).

10. Bronze Mounting: Built as integral unit mounted over, or supported on, cast-iron base and of sufficient dimensions to be structurally sound and adequate for imposed forces.

11. Gear Cases: Cast iron; furnished on 18-inch and larger valves and of extended type with steel side plates, lubricated, gear case enclosed with oil seal or O-rings at shaft openings.

12. Stuffing Boxes: Located on top of bonnet and outside gear case.


WATER PLANTS

GATE VALVES 15043-4

H. Gate valves 14 inches to 48 inches: Provide AWWA C 515; reduced-wall, resilient seated gate valves with 250 psig pressure rating. Furnish with spur or bevel gearing.

1. Mount valves horizontally if proper ground clearance cannot be achieved by normal vertical installation. For horizontally mounted gate valves, provide bevel operation gear mounted vertically for above ground operation.

2. Use valve body, bonnet, wedge, and operator nut constructed of ductile iron. Fully encapsulate exterior of ductile iron wedge with rubber.

3. Ensure wedge is symmetrical and seals equally well with flow in either direction.

4. Provide ductile iron operator nut with four flats at stem connection to apply even input torque to the stem.

5. Bolts: AWWA C515, Section 4.4.4, Stainless Steel; cadmium plated or zinc coated.

6. Provide high strength bronze stem and nut.

7. O-rings: AWWA C515, Section 4.2.2.5, pressure O-rings as gaskets.

8. Provide stem sealed by three O-rings. Top two O-rings are to be replaceable with valve fully open at full rated working pressure.

9. Provide thrust washers to the thrust collar for easy valve operation.

I. Knife Gate Valves: Provide Bi-directional knife gate valve with 150 psig pressure rating. Comply with following requirements unless otherwise specified on Drawings:

1. Body: 316 Stainless Steel

2. Gate: 316 Stainless Steel

3. Seat: EPDM

4. End Connection: ANSI B16.5

J. Gate Valves Extension Stem: When shown on Drawings, provide non-rising, extension stem having coupling sufficient to attach securely to operating nut of valve. Upper end of extension stem shall terminate in square wrench nut no deeper than 4 feet from finished grade or as shown on Drawings. Support extension stem with an arm attached to wall of manhole or structure that loosely holds extension stem and allows rotation in the axial direction only.

K. Gate Valves in Factory Mutual (Fire Service) Type Meter Installations: Conform to provisions of this specification; outside screw and yoke valves; carry label of Underwriters' Laboratories, Inc.; flanged, Class 125; clockwise to close.

L. Gate Valves for Tapping Steel Pipe: Provide double disc gate valve. Resilient wedge gate valve shall only be installed in a vertical position.


WATER PLANTS

GATE VALVES 15043-5

M. Provide flanged joints when valve is connected to steel or PCCP.

N. Key valve stem into the operator nut.

O. Do not exceed 600 ft-lbs of torque on operator nut on gate valve.

PART 3 EXECUTION 3.1 INSTALLATION

A. Earthwork. Conform to applicable provisions of Section 02315 – Excavation, Trenching and Backfilling for Utilities.

B. Operation. Do not use valves for throttling without prior approval of manufacturer.

3.2 SETTING VALVES AND VALVE BOXES

A. Remove foreign matter from within valves prior to installation. Inspect valves in open and closed positions to verify that parts are in satisfactory working condition.

B. Install valves and valve boxes where shown on Drawings. Set valves plumb and as detailed. Center valve boxes on valves. Carefully tamp earth around each valve box for minimum radius of 4 feet, or to undisturbed trench face when less than 4 feet. Install valves completely closed when placed in water line.

C. For pipe section of each riser, use only 6 inch, ductile iron Class 51, or DR18 PVC pipe cut to proper length. Riser must be installed to allow complete access for operation of valve. Assemble and brace box in vertical position as indicated on Drawings.

3.3 TESTING

A. Test as required by Section 15032 – Testing Piping Systems.

B. Double-Disc Gate Valves: Apply hydrostatic test pressure equal to twice rated working pressure of valve between discs. Valve shall show no leakage through metal, flanged joints, or stem seals. Test at rated working pressure, applied between discs. Valve shall show no leakage through metal, flanged joints, or stem seals. Do not exceed leakage rate of 1 oz/hr/inch of nominal valve size.

C. Solid-Wedge Gate Valves: Apply hydrostatic pressure equal to twice rated working pressure of valve with both ends bulkheaded and gate open. Valve shall show no leakage through metal, flanged joints, or stem seals. Test at rated working pressure, applied through bulkheads alternately to each side of closed gate with opposite side open for inspection. Valve shall show no leakage through metal, flanged joints, or stem-seals. Do not exceed leakage rate of 1 oz/hr/inch of nominal valve size.

D. Repair or replace valves which exceed leakage rate.


WATER PLANTS

GATE VALVES 15043-6

3.4 PAINTING OF VALVES

A. Paint valves in vaults, stations, and above ground with approved paint, in accordance with Section 09928 – Protective Coating Systems.

END OF SECTION


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FIRE HYDRANTS 15045-1

SECTION 15045

FIRE HYDRANTS

PART 1 - GENERAL


A. Fire hydrants.

B. Adjustment of fire hydrants and gate valves.

1.2 REFERENCES

A. AWWA C 502 – Standard for Dry Barrel fire Hydrants (Latest Edition).

B. AWWA C 550 - Standard for Protective Epoxy Interior Coatings for Valves and Hydrants

C. SSPC SP2 - Hand Tool Cleaning

D. SSPC SP3 - Power Tool Cleaning

E. SSPC SP10 - Near-White Blast Cleaning

F. SSPC SP11 - Power Tool Cleaning to Bare Metal

G. SSPC Paint Spec No.21

H. SSPC-Paint 21 - White or Colored Silicone Alkyd Paint

I. SSPC-Paint 25 - Zinc Oxide, Alkyd, Linseed Oil Primer for Use Over Hand Cleaned Steel, Type I and Type II

J. SSPC-Paint 104 - White or Tinted Alkyd Paint

K. Federal Standard A-A-2962A - Enamel, Alkyd, Solvent Based Low VOC

1.3 SUBMITTALS

A. Conform to requirements of Section 01330 – Submittal Procedures.

B. Submit name of hydrant manufacturer, type of bonnet paint, and engineering control drawing number for hydrant proposed for use.

PART 2 - PRODUCTS

2.1 HYDRANTS

A. Provide fire hydrants in conformance with AWWA C 502, Standard for Dry Barrel Fire Hydrants (Latest Edition). Hydrants are approved by the City for issuance of a Certificate of Responsibility. Only hydrants with current Certification of Responsibility will be allowed in City of Conroe projects.

B. The Owner’s Representative may, at any time prior to or during installation of hydrants, randomly select furnished hydrant for disassembly and laboratory inspection, at City expense, to verify compliance with Specifications. When hydrant is found to be non-compliant, replace, at Contractor's expense, hydrants, with hydrants that comply with Specifications.


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C. Provide lower hydrant barrel fabricated from Ductile Iron Pipe as single piece, connected to upper hydrant barrel by means of joint coupling that will provide three hundred sixty degree (360) rotation of upper barrel.

2.2 LEADS

A. Branches (Leads): Conform to requirements of Section 15106 - Ductile Iron Pipe and Fittings.

2.3 HYDRANT PAINTING

A. New hydrants and refurbished hydrants shall be shop coated as specified herein.

B. Exterior Above Traffic Flange ( Including Bolts & Nuts ).

1. Surface preparation to be in accordance with SSPC-SP 10 (NACE 2) near white blast cleaned surface.

2. Coat with three coat alkyd/silicone alkyd system with total dry film thickness (DFT) of 6 - 9 mils as follows:

a) Prime Coat - Oil modified alkyd primer, to be in general conformance with SSPC Paint Specification No. 25. Total dry film thickness (DFT) 2 - 3 mils.

b) Intermediate Coat - Heavy Duty Industrial Alkyd Enamel to be in general conformance with SSPC Paint Specification No. 104, and Federal Standard AA- 2962A. Total dry film thickness (DFT) of 2 -3 mils.

c) Finish Coat - Silicone Alkyd Resin Enamelto be in general conformance with SSPC Paint Specification No. 21. Total dry film thickness (DFT) to be 2 – 3 mils. Exception - hydrant bonnet shall not be finished shop coated, only intermediate coated. Install color coded finish coating of bonnet in field.

d) Bonnet Paint - Field apply finish coat of Silicone Alkyd Resin Enamel to be in general conformance with SSPC Paint Specification No. 21. Dry film thickness of 2 - 3 mils. Bonnet colors are to be as specified in Paragraph 3.01 to designate the appropriate size of water supply line.

3. Colors - Primer: Manufacturer’s standard color. Finish coat of hydrant body: ACRO 555 Crystal Blue or equivalent. Connection caps: Finished coated white. Paint white band of finish coat two (2) inches in width on hydrant body approximately six inches (6") above and parallel to traffic flange. Intermediate coat: Contrasting color to blue finish, such as white.

C. Field Maintenance Painting (Exterior Above Traffic Flange)

1. Surface Preparation to be in accordance with SSPC - SP2, Hand Tool Cleaning, or SSPC - SP3, Power Tool Cleaning, depending on condition of existing paint and extent of corrosion. It is not necessary to remove tightly adhered mill scale, rust, and paint. Mill scale, rust and paint are considered tightly adherent when they cannot be removed with dull putty knife. In some severe cases where it is necessary to remove majority of existing paint, surface should be cleaned in accordance with SSPC -SP11, Power Tool Cleaning to Bare Metal.

2. When surface is cleaned to bare metal (SSPC - SP11), coat hydrant with three coat Alkyd/Silicone Alkyd system in accordance with Paragraph 2.03.B.2 as for new hydrants. When surface is cleaned to SSPC - SP2 or SSPC - SP3, coat hydrant with Silicone Alkyd Resin Enamel in general conformance with SSPC Paint Specification No. 21. Total dry film thickness of 3-6 mils.


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D. Exterior Below Traffic Flange (including lower barrel extensions).

1. Surface preparation in accordance with SSPC- SP10 (MACE 2) Near White Blast Cleaned Surface.

2. Primer and intermediate coat: coal tar epoxy in general conformance with SSPC Paint Specification No. 16. Apply two (2) coats with dry film thickness (DFT) of 8 – 10 mils each for total DFT of 16 -20 mils.

3. Finish coat: Water based vinyl acrylic mastic Apply one coat with dry film thickness of 6 - 8 mils. Color of finish coat to be same as finish coat for exterior above traffic flange, i.e., blue. (Acro 555 Crystal Blue, or equivalent.)

E. Interior Surfaces Above and Below Water Line Valve (including lower barrel extensions)

1. Material used for internal coating of hydrant interior ferrous surfaces must be NSF certified as suitable for contact with potable water as required by Chapter 290, Rules and Regulations for Public Water Systems, Texas Commission on Environmental Quality.

2. Coating shall be liquid or powder epoxy system in accordance with AWWA Standard C - 550 (latest revision). Coating may be applied in two or three coats, according to manufacturer's recommendations, for total dry film thickness of 12 -18 mils.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Set fire hydrant plumb and brace at locations and grades as shown on Drawings. When barrel of hydrant passes through concrete slab, place 1-inch-thick piece of standard sidewalk expansion joint material around section of barrel passing through concrete.

B. Locate nozzle center line minimum 18 inches above finish grade.

C. Place 12-inch by 12-inch yellow indicators (plastic, sheet metal, plywood, or other material approved by Owner’s Representative) on pumper nozzles of new or relocated fire hydrants installed on new water lines not in service. Remove indicators after new water line is tested and approved by Owner’s Representative.

D. Do not cover drain ports when placing concrete thrust block.

E. Obtain Owner’s Representative's approval in writing prior to installation of hydrants which require changes in bury depth due to obstructions not shown on Drawings. Unit price adjustments will not be allowed for changes in water line flow line or fire hydrant barrel length caused by obstructions.

F. Plug branch lines to valves and fire hydrants shown on Drawings to be removed. Deliver fire hydrants designated for salvage to nearest Utility Maintenance Quadrant Facility.

G. Install branches (leads) in accordance with Section 15106 - Ductile Iron Pipe and Fittings.


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H. Coating Requirements:

1. Apply coatings in strict accordance with manufacturer's recommendations. No requirements of this specification shall cancel or supersede written directions and recommendations of specific manufacturer so as to jeopardize integrity of applied system.

2. Furnish affidavit of compliance that coatings furnished complies with requirements of this specification and referenced standards, as applicable.

I. Use color code for field coating of hydrant bonnet as directed by Owner’s Representative.

J. Remove and dispose of unsuitable materials and debris in accordance with requirements of Section 01750 - Waste Material Disposal.

END OF SECTION


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MECHANICAL GENERAL PROVISIONS 15050-1

SECTION 15050

MECHANICAL GENERAL PROVISIONS PART 1 GENERAL

1.1 GENERAL

A. Except as modified in this section, General Conditions, Supplementary Conditions, applicable provisions of Division 1 - General Requirements, and other provisions and requirements of the contract documents apply to work of Division 15 - Mechanical.

B. Applicable provisions of this section apply to all sections of Division 15 - Mechanical.

C. Contract drawings are diagrammatic only and do not give fully dimensioned locations of various elements of work. Determine exact locations from field measurements.

D. Where the word “concealed” is used in connection with insulating, painting, piping, ducts and the like, the word is understood to mean hidden from sight as in chases, furred spaces or above suspended ceilings. “Exposed” is understood to mean open to view.

1.2 CODE REQUIREMENTS AND PERMITS

A. Perform work in accordance with applicable statutes, ordinances, codes, and regulations of governmental authorities having jurisdiction.

B. Resolve any code violation discovered in contract documents with the Architect/Engineer prior to award of the contract. After award of the contract, make any correction or addition necessary for compliance with applicable codes at no additional cost to Owner.

C. Obtain and pay for all permits and inspections.

1.3 REFERENCE SPECIFICATIONS AND STANDARDS

Materials which are specified by reference to Federal Specifications; ASTM, ASME, ANSI, or AWWA Specifications; Federal Standards; or other standard specifications must comply with latest editions (except where specified otherwise in individual sections), revisions, amendments or supplements in effect on date bids are received. Requirements in reference specifications and standards are minimum for all equipment, material and work. In instances where capacities, size or other feature of equipment, devices or materials exceed these minimums, meet listed or shown capacities.

1.4 ASBESTOS

Prior to beginning any work in existing buildings, Contractor shall provide a letter to the Owner stating that he has examined the remodeling areas of the building for asbestos materials and giving results of his findings. If at any time during construction asbestos is encountered, stop work immediately and contact Architect/Engineer.


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1.5 SUBMITTAL DATA AND SHOP DRAWINGS

A. Material and Equipment List. Within 30 days after award of the contract and before orders are placed or shop drawings are submitted, submit a list of equipment and principal materials specified. Give names of manufacturers, catalog and model numbers, and such other supplementary information as necessary for identification.

B. Material and Equipment Shop Drawings. Submit all detailed shop drawings, descriptive literature, physical data, and performance data at one time for review for items of equipment and for principal materials proposed for installation. Include identifying symbols and equipment numbers used in plans and specifications, with reference to specification paragraphs, and drawing numbers of all equipment and material submitted. Ductwork and piping shop drawings are not required; do not submit.

C. Final Submittal. In addition to number of copies of shop drawings and other data required for review submittals, maintain a separate file of final approved copies of such material. Deliver approved copies in a hard-back binder for the Owner’s use. Incorporate changes and revisions made throughout construction period. Delivery of approved copies is a condition of final acceptance for the project.

D. Contractor’s Check. Shop drawings will be submitted only by the Contractor. Indicate by signed stamp that the drawings have been checked, that the work shown on the drawings is in accordance with contract requirements and that dimensions and relationship with work of other trades have been checked. If drawings are submitted for approval that have not been checked and signed by the Contractor, they will be returned for checking before being considered by the Architect/Engineer.

1.6 OPERATING AND MAINTENANCE INSTRUCTIONS

A. The Contractor shall furnish five copies of commercially available standard operation and maintenance data, including operating instructions, maintenance instructions and parts listings. Detailed requirements for these items are as follows:

1. Information required for the preparation of O&M manuals may be furnished in the form of manufacturers’ standard brochures, schematics, and other printed instructions. Clearly distinguish between information which applies to the equipment and information which does not apply. Data shall include as a minimum the following items: a. Recommended procedures and frequencies for preventive maintenance;

inspection, adjustment, lubrication, cleaning, etc. b. Special tools and equipment required for testing and maintenance. c. Parts lists reflecting the true manufacturer’s name, part number and

nomenclature. d. Recommended spares by part number and nomenclature and spare

stocking levels. e. Integrated mechanical and electrical system schematics and diagrams to

permit operation and troubleshooting after acceptance of the system. f. Troubleshooting, checkout, repair and replacement procurement

procedures.


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g. Operating instructions including start-up and shutdown procedures. h. Safety considerations including load limits, speed, temperature and

pressure. 2. Provide O&M manuals for all HVAC and plumbing equipment.

B. Upon completion of work, and at time designated by the Architect/Engineer, provide services of a competent representative of the Contractor for a period of at least 40 hours to instruct the Owner’s personnel in the operation and maintenance of the entire system.


A. Preparation. Maintain at the job site a separate set of white prints of the contract drawings for the sole purpose of recording the “as-built” changes and diagrams of those portions of work in which actual construction is significantly at variance with the contract drawings. Mark the drawings with a colored pencil. Prepare, as the work progresses and upon completion of work, drawings clearly indicating locations of various equipment and other pertinent items, as installed.

B. Deliver. At conclusion of project, obtain without cost to Owner, reproducibles of original mechanical drawings and transfer as-built changes to these. Delivery of as-built prints and reproducibles is a condition of final acceptance. Provide a CD with as built drawings.

1.8 GUARANTEE

Guarantee work for 1 year from the date of substantial completion of the project, and during that period make good any faults or imperfections that may arise due to defects or omissions in materials or workmanship.

1.9 SERVICE

Perform service work required during the guarantee period including lubrication of bearings. Perform manufacturer’s recommended quarterly (every 3 months) service, and provide the Owner with a written report of each quarterly service. Cleaning of air filters and pipe strainers is not included.

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT

Furnish new and unused materials and equipment of domestic manufacture. Where two or more units of same type or class of equipment are required, provide units of a single manufacturer.


The acceptable manufacturers are listed in individual sections of Division 15. Where two or more units of same type or class of equipment are required, provide units of a single manufacturer. Manufacturers’ names and catalog numbers specified under sections of Division 15 are used to establish standards of design, performance, quality and serviceability and not to limit competition. Equipment of similar design, equal to that specified, from one of the named manufacturers will be acceptable on approval of the Architect/Engineer.


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A. Substitution.

1. If the Contractor desires to substitute a material or method as an equal to the specified item, he shall request permission from the Architect/Engineer, in writing, and shall include such literature, samples, etc., deemed necessary to establish the equal quality of his proposal. If the Architect/Engineer deems it necessary in order to establish the equality between two or more products, he may require laboratory testing at the Proposer’s expense in order to obtain information upon which to base a decision. The Architect/Engineer will not give approval to material salesmen or subcontractors, and only in writing to the Contractor.

2. For each proposed substitution product, clearly show how the proposed product meets the requirements of the specifications, including performance and space requirements.

3. No substitution will be considered unless it is presented in writing within that number of days after Notice to Proceed equal to 15 percent of the contract time.

4. Proposers of substitute products shall present samples, literature, test and performance data, record of other installations, names of owners, architects, engineers, contractors and subcontractors as references, statement of current financial condition, and other technical information applicable to their products, to aid in determining the worth of the substitute product offered in relation to the material and work specified from the standpoint of the Owner’s best interest. Substitute materials and products shall be used only if approved in writing by the Architect/Engineer in advance.

5. Approval of substitute materials offered shall not be a basis for contingent extra charges because of changes in other work or related work, such as roughing-in, electrical, structural or architectural, which may result from the substitution.

2.3 NOISE AND VIBRATION

Select equipment to operate with minimum noise and vibration. If objectionable noise or vibration is produced or transmitted to or through the building structure by equipment, piping, ducts or other parts of work, rectify such conditions without cost to the Owner. If the item of equipment is judged to produce objectionable noise or vibration, demonstrate (without cost to the Owner) that equipment performs within designated limits on the vibration chart included at the end of this section.

2.4 AIR FILTERS

Immediately prior to final acceptance of project, inspect, clean and service air filters. Replace disposable type air filters if dirty.

2.5 ACCESS DOORS

Locate access doors for all walls or ceiling locations, as required or shown, to valves, controls, regulating devices, water arresters, fire dampers, air distribution boxes and other concealed equipment requiring maintenance adjustment or operation.


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PART 3 EXECUTION

3.1 SPACE REQUIREMENTS

Consider space limitations imposed by contiguous work, including clearances required for service, in selection and location of equipment and material. Do not provide equipment or material which is not suitable in this respect.

3.2 OBSTRUCTIONS

A. The drawings indicate certain information pertaining to surface and subsurface obstructions which has been taken from available drawings. Such information is not guaranteed, however, as to accuracy of location or complete information.

B. Before any cutting or trenching operations are begun, verify with Owner’s representative, utility companies, municipalities, and other interested parties that all available information has been provided. Verify locations given.

C. Should obstruction be encountered, whether shown or not, alter routing of new work, reroute existing lines, remove obstruction where permitted, or otherwise perform whatever work is necessary to satisfy the purpose of the new work and leave existing services and structures in a satisfactory and serviceable condition.

D. Assume total responsibility for and repair any damage to existing utilities or construction, whether or not such existing facilities are shown.

3.3 OPENINGS

Framed, cast or masonry openings for ductwork, equipment and piping are specified under other divisions. However, drawings and layout work for exact size and location of all such openings are included under this division.

3.4 PROTECTION

Adequately protect work, equipment, fixtures and materials. At work completion, all work must be clean and in good condition.

3.5 LUBRICATION

A. Provide a complete charge of correct lubricant for each item of equipment requiring lubrication.

3.6 OPERATING TESTS

After all mechanical systems have been completed and put into operation, subject each system to an operating test under design conditions to ensure proper sequence and operation throughout the range of operation. Make adjustments as required to ensure proper functioning of all systems. Special tests on individual systems are specified under individual sections.

END OF SECTION


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EQUIPMENT BASES AND SUPPORTS 15060-1

SECTION 15060

EQUIPMENT BASES AND SUPPORTS

PART 1 GENERAL

1.1 SUMMARY

Provide concrete equipment pads for all direct and isolated floor mounted equipment, and structural equipment supports for horizontal tanks, heat exchangers and similar equipment or pipe, where required.

1.2 SUBMITTALS

Submit shop drawings on all structural supports.

PART 2 PRODUCTS

2.1 CONCRETE

Provide concrete in accordance with Section 03310 – Cast-in-Place Concrete.

2.2 STRUCTURAL METAL

Construct floor stands of structural members or steel pipe for equipment supports.

PART 3 EXECUTION

3.1 CONCRETE PADS

Pour 4-inch pads on roughened floor slabs unless otherwise noted. Reinforce pad with No. 4 rebar set 12 inches on center unless indicated otherwise on structural drawings. Provide 2-inch clearance between top of pad and rebar. Extend outer edges of pads a minimum of 2 inches beyond equipment. Secure equipment with anchor bolts in accordance with equipment installation instructions.

3.2 STRUCTURAL SUPPORTS

A. Bolt floor stands to concrete pads.

B. Hang ceiling-mounted equipment from suitable brackets, platform framing or similar supports fabricated of structural members according to Section 05450.

C. Paint in accordance with Section 09928.

END OF SECTION


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EQUIPMENT BASES AND SUPPORTS 15060-2

BLANK PAGE


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PIPE AND PIPE FITTINGS 15105-1

SECTION 15105

PIPE AND PIPE FITTINGS

PART 1 GENERAL

This section specifies pipe and pipe fittings for all piping systems. The section applies to all sections of the specifications that employ pipe and pipe fittings.

1.1 RELATED WORK


B. Testing Piping Systems. Section 15032.

C. Protective Coating Systems. Section 09928.

D. Ductile Iron Pipe and Fittings. Section 15106


Employ welders qualified to perform welding operations required either by certifications or by submitting to required tests per American Welding Society requirements. Contractor shall submit documentation for all welders on the job.

1.3 SUBMITTALS

Submit manufacturer's product data showing compliance with requirements of Part 2.


Deliver, store and protect products under provisions of Section 01600.

1.5 REFERENCES

A. AASHTO - Standard Specifications for Highway Bridges.

B. AREA - Manual for Railway Engineering, Volume II, Chapter 15.

C. ASTM A 36 - Standard Specification for Structural Steel.

D. ASTM A 53 - Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated Welded and Seamless.

E. ASTM A 135 - Standard Specification for Electric-Resistance-Welded Steel Pipe.

F. ASTM A 139 - Standard Specification for Electric-Fusion (ARC) - Welded Steel Pipe (NPS 4 and Over).

G. ASTM A 570 - Standard Specification for Steel, Sheet and Strip, Carbon, Hot-Rolled, Structural Quality.

H. ASTM D 4541 - Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion Tests.

I. AWWA C 200 - Steel Water Pipe 6 in. and Larger.

J. AWWA C 205 - Cement-Mortar Protective Lining and Coating for Steel Water Pipe.

K. AWWA C 206 - Standard for Field Welding of Steel Water Pipe.

L. AWWA C 207 - Standard for Steel Pipe Flanges for Waterworks Service - Sizes 4 in. through 144 in.

M. AWWA C 208 - Dimensions for Fabricated Steel Water Pipe Fittings; Addendum C 208A.


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N. AWWA C 209 - Cold-Applied Tape Coatings for the Exterior of Special Sections, Connections and Fittings for Steel Water Pipelines.

O. AWWA C 210 - Liquid Epoxy Coating Systems for the Interior and Exterior of Steel Water Pipelines.

P. AWWA C 214 - Tape Coating Systems for the Exterior of Steel Water Pipelines.

Q. AWWA C 602 - Cement-Mortar Lining of Water Pipelines - 4 in. (100 mm) and Larger - In Place.

R. AWWA M 11 - Steel Pipe - A Guide for Design and Installation.

S. SSPC Good Painting Practice, Volume 1

T. SSPC PA 2 - Paint Application Specification No. 2 Measurement of Dry Paint Thickness with Magnetic Gauges.

U. SSPC SP 1 - Surface Preparation Specification No. 1 Solvent Cleaning.

V. SSPC SP 6 - Surface Preparation Specification No. 6 Commercial Blast Cleaning.

W. SSPC SP 10 - Surface Preparation Specification No. 10 Near-White Blast Cleaning.

X. SSPC VIS 1 - Visual Standard for Abrasive Blast Cleaned Steel

PART 2 PRODUCTS


Acceptable manufacturers are specified with individual component type where applicable for this section.

2.2 PIPE AND FITTINGS

The particular type of pipe and fittings for each system is specified in the section on that system. As a minimum, pipe shall conform to the following.

A. Cast Iron Soil Pipe and Fittings.

1. Provide service weight cast iron no-hub soil pipe and fittings with stainless steel band/neoprene gasket type no-hub couplings. Each clamp shall bear the FM and UPC stamp, and shall be approved to Class I of Factory Mutual Standard No. 1680, shall be rated for 15 psi working pressure, and be equal to Clamp-All. All materials used in the clamp shall be stainless steel. At Contractor’s option, provide bell-and-spigot soil pipe and fittings per paragraph 2.3, F below. All elbows and tees (in no-hub or bell-and-spigot) shall be braced against thrust loads which might result in joint separation due to dynamic forces caused by sudden, heavy rainfall conditions.

2. Pipe shall be factory hot dip coated per ASTM A 74.

B. Steel Pipe and Fittings, 2 1/2 inch and Smaller.

1. Steel pipe shall conform to ASTM A 53, galvanized, except that spiral lap welded pipe may not be used. Unless otherwise specified or shown on the drawings, all pipe shall be Schedule 40.

2. Fittings for use with steel pipe with threaded joints shall be 150-pound malleable iron screwed fittings in accordance with ANSI B16.3. Provide pipe with American Standard taper pipe threads. Unions shall be 150 pound malleable iron, ground-joint unions with bronze seat.


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C. Steel Pipe and Fittings, 3” to 24”.

1. Provide steel pipe designed and manufactured in conformance with AWWA C 200 and AWWA Manual M-11 except as modified herein. Steel shall be minimum of ASTM A 36 with 42 KSI minimum yield, ASTM A 572 Grade 42, ASTM A 53 Grade B, ASTM A 139 Grade C or API equivalent

2. Pipe shall have factory primed exterior compatible with specification section 09928. Interior lining shall be NSF 61 approved Ceramic Epoxy.

3. Fittings for use with steel pipe shall be grooved end coupled, flanged or butt welded.

2.3 JOINTS

A. Screwed. Make screwed joints using machine-cut USASI taper pipe threads. Apply a suitable joint compound to the male threads only. Ream the pipe to full inside diameter after cutting. All-thread nipples are not permitted.

B. Dissimilar Metals. Make joints between copper and steel pipe and equipment using insulating unions such as Crane Company No. 1259; EPCO as manufactured by EPCO Sales, Inc.; or an approved substitution. Joints between above-ground and below-ground piping is considered the same as joints between dissimilar metals.

C. Welded. Make welded joints as recommended by the standards of the American Welding Society. Ensure complete penetration of deposited metal with base metal. Provide filler metal suitable for use with base metal. Keep inside of fittings free from globules of weld metal. Do not use mitered joints.

D. Flanged.

1. Prior to installation of bolts, accurately center and align flanged joints to prevent mechanical prestressing of flanges, pipe and equipment. Align bolt holes to straddle the vertical, horizontal or north-south centerline. Do not exceed 3/64 inch per foot inclination of the flange face from true alignment.

2. Use flat-face companion flanges only with flat-faced fittings, valves or equipment. Use flat-faced flanges for cast iron and ductile iron pipe and raised-face flanges for all steel pipe unless otherwise noted. Use flange material to match pipe material.

3. Install proper gaskets, suitable for intended service and factory cut to proper dimensions. Secure with a suitable gasket cement.

4. Use ASTM A 307, Grade B hex bolts and heavy hex nuts conforming to ANSI B18.2.1 and B18.2.2, respectively. Use hot-dipped galvanized nuts and bolts for galvanized pipe and flanges. Use Type 304 stainless steel and bolts for all below-ground flanges.

5. Use carbon steel flanges conforming to AWWA C 207 Class F and ANSI B16.5. Materials shall conform to ASTM A 105, Grade II or ASTM A 108, Grade II. Use slip-on type flanges on pipe only. Use welding neck type flanges on all fittings. Weld slip-on flanges inside and outside.

6. Gray iron and ductile iron flanges shall be rated for 250 psi service and drilled with 125-pound bolt circle, conforming to ANSI B16.1 with materials conforming to AWWA C115.

7. Keep flange covers on equipment and shop-fabricated piping until ready to install in system.


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E. No Hub. Install according to manufacturer's recommendations, using recommended tools.

F. Bell and Spigot. Provide ASTM A 74 hot-dip coated, service weight cast iron bell-and-spigot soil pipe and fittings with ASTM C 564 elastomeric gaskets.

G. Victaulic Joints.

1. The Contractor may use grooved-end pipe and fittings with grooved-end couplings in lieu of flanged joints. Victaulic or grooved-end type couplings shall not be allowed in pipe systems with positive displacement pumps or pulsating flow characteristics.

2. Grooved-end couplings shall be galvanized when used on galvanized pipe. When used on piping which is to be coated in accordance with Specification Section 09928, the inner and outer surfaces of the couplings shall receive a matching protective coating prior to installation if necessary.

3. Grooved-end couplings for use with ductile iron pipe shall be Victaulic Style 31 or approved substitution. Couplings for use with steel pipe shall be Victaulic Zero-Flex, Style 07, rated for 250 psi minimum working pressure or approved substitution.

4. Bolts and nuts for grooved-end couplings shall be heat-treated carbon steel, track-head bolts and hex nuts. When galvanized couplings are used, bolts and nuts shall be plated. For grooved-end couplings installed in the wet well, Type 316 stainless steel bolts and nuts shall be provided.

5. Gaskets for grooved-end couplings shall be Buna-N (Victaulic Grade T). Use flush-seal gaskets with ductile iron pipe; gaskets for use with cement-lined steel pipe shall be captured between the ends of the pipe to protect the exposed metal from corrosion.

2.4 FITTINGS

A. Use fittings of same size as pipe they serve. Reducers are not permitted to facilitate an off-size fitting. Reducing bushings are also prohibited. Reduction in piping size will be made by reducing fittings. Fittings shall be lined and coated as specified for pipe they serve. Fittings for use with galvanized pipe shall be galvanized in accordance with ASTM A 153.

B. Screwed Fittings. Fittings for use with steel pipe with threaded joints shall be 150-pound malleable iron screwed fittings in accordance with ANSI B16.3. Provide pipe with American Standard Taper pipe threads. Drainage fittings for use with drain lines and other lines which are required to be graded shall be cast iron drainage screwed fittings in accordance with ANSI B16.12.

C. Flanged Fittings. Fittings for use with flanged joints on steel pipe shall be carbon steel flanges conforming to AWWA C 207 Class F and ANSI B16.5. Materials shall conform to ASTM A 105, Grade II or ASTM A 108, Grade II Lining and seal coating of fittings shall be in accordance with the specific pipe specification section. Use welding neck type flanges on all fittings.

D. Butt-Welded Fittings. ASTM A 105 or A 350 forged steel butt-weld fittings manufactured in accordance with ANSI B16.9.


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E. Grooved-End Fittings.

1. Grooved-end fittings for use with ductile iron pipe with grooved ends (victaulic-type joints) shall be rigid radius grooved and shall be cast iron conforming to ASTM A 48, Class 30-A, or ductile iron conforming to ASTM A 536, Grade 60-45-10. Fittings shall conform to the dimensional requirements of AWWA C110, except for end preparation.

2. Grooved-end fittings for use with steel pipe with grooved ends shall be cut-grooved and shall be malleable iron conforming to ASTM A 47, Grade 32510, or ductile iron conforming to ASTM A 536, Grade 60-45-10, or forged steel conforming to ASTM A 106, Grade B.

3. Grooved-end fittings shall be manufactured by the grooved-end coupling manufacturer.

4. All grooved-end fittings shall be cement mortar lined unless otherwise noted.

2.5 BRANCH CONNECTIONS

A. Galvanized Steel Pipe. Use threaded or grooved coupled straight size reducing tee, hot-dipped galvanized. When branch is smaller than header, a hot-dipped galvanized nipple and reducing coupling or swaged nipple may be used.

B. Black Steel Pipe. For 3 inches and larger welding pipe, when branch size is the same size as header, use welding tee. When the branch is smaller than the header, use weldolets. For threaded branch connections, use 3000-pound threadolets.

C. Cast or Ductile Iron Pipe. For 2 inches and smaller, use branch connections for drain tappings in conformance with ANSI B16.1-1967. For all other branch connections, use fitting makeup.

2.6 UNIONS

A. Malleable Iron Unions. Use 150-pound standard (300-pound WOG) malleable iron, ground joint unions with bronze seat. Provide flanged union joints on piping 2-1/2 inches and larger. Use service galvanized unions for galvanized pipe. Use insulating unions where indicated or required where joining dissimilar metals.

2.7 GASKETS

A. Provide gaskets of neoprene, unless otherwise noted.

B. Provide full-face gaskets for flat-faced flanged and ring gaskets for raised-face flanges. Use 1/16-inch thick gaskets for pipe smaller than 6 inches and 1/8-inch thick gaskets for pipe 6 inches and larger. Gaskets' dimensions shall conform to ANSI B16.21.

C. Provide insulating flange gasket kit where indicated or required where joining dissimilar metals.

2.8 PIPE SUPPORTS

Provide standard Unistrut metal framing members and appurtenances for pipe support where shown. Mult-A-Frame and Power-Strut pipe support systems also are acceptable. Hot-dip galvanize all such members and appurtenances.

2.9 PIPE SLEEVES

Sleeves below grades in outside walls are detailed on drawings. Provide Thunderline Link-Seal with cadmium-plated nuts and bolts, with cast iron pressure plate.


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2.10 FIRESTOPPING

Voids between sleeves or core-drilled holes and pipe passing through fire rated assemblies shall be firestopped to meet the requirements of ASTM E 814. Contractors shall provide proper sizing when providing sleeves or core-drilled holes to accommodate their through-penetrating items.

PART 3 EXECUTION

3.1 PREPARATION

A. Ream pipe and tube ends to remove burrs.

B. Remove scale and dirt on inside and outside before assembly.

3.2 PIPE FABRICATION AND INSTALLATION

A. Make piping layout and installation in the most advantageous manner possible with respect to headroom, valve access, opening and equipment clearance, and clearance for other work. Give particular attention to piping in the vicinity of equipment. Preserve the maximum access to various equipment parts for maintenance.

B. Do not cut or weaken any structural member.

C. Cut all pipes accurately to measurement determined at the site. After cutting pipe, ream it to remove burrs.

D. Install piping neatly, free from unnecessary traps and pockets. Work into place without springing or forcing. Use fittings to make all changes in direction. Field bending and mitering are prohibited. Make all connections to equipment using flanged joints or unions. Make reducing connections with reducing fittings only.

E. Handling. Handle pipe, fittings and accessories in a manner that will ensure their installation in the work in sound, undamaged condition. In unloading, reloading, hauling and laying pipe and fittings, use proper equipment, tools and methods to prevent damage. Hooks inserted in ends of pipe must have broad, well-padded contact surfaces.

F. Cutting Pipe. Perform cutting of cast iron pipe in a neat manner, without damage to pipe or to the cement lining. Cut pipe smooth, straight and at right angles to pipe axis with mechanical pipe cutters. In locations where use of mechanical cutters would be difficult or impractical, existing pipe may be cut with diamond-point chisels, saws or other tools which will cut pipe without damaging impact or shock.

G. Cleaning. Clean interior of all pipe and fittings thoroughly of all foreign matter before installing and keep clean until the work has been accepted. Remove all lumps, blisters and excess coating from exterior spigot and interior bell surfaces. Wire brush such surfaces and wipe clean and dry, free from oil and grease, before placing spigot into bell. Keep joint contact surfaces clean until jointing is completed. Take every precaution to prevent foreign material from entering pipe while it is being installed. Do not place debris, tools, clothing or other materials in pipe.

H. Laying Pipe. Protect pipe from lateral displacement by means of pipe embedment material installed as provided in trench backfill specification.

1. Do not under any circumstances lay pipe in water or under unsuitable weather or trench conditions.

2. Lay pipe with bell ends facing direction of laying except when making closures.

3. Lay pipe on bedding as specified in the section on Excavation, Trenching and Backfilling for Utilities, as required in individual pipe material specification.


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4. Excavate trenching for underground piping to the required depth to ensure 3 feet minimum cover over the pipe unless otherwise indicated on the drawings. Excavation and backfill shall be performed in accordance with Division 2.

3.3 WELDING

A. Weld and fabricate piping in accordance with ANSI Standard B31.1, latest edition, Code for Pressure Piping. Machine beveling in shop is preferred. Field beveling may be done by flame cutting to recognized standards.

B. Align piping, fittings and equipment so that no part is offset more than 1/16 inch. Set all fittings and joints square and true, and preserve alignment during welding operation. Use of alignment rods inside pipe is prohibited.

C. Do not permit any weld to project within the pipe in excess of 1/16 inch so as to restrict it. Tack welds, if used, must be of the same material and made by the same procedure as the completed weld. Otherwise, remove tack welds during welding operation.

D. Do not split, bend, flatten or otherwise damage piping before, during or after installation.

E. Remove dirt, scale and other foreign matter from inside piping before tying in sections, fittings, valves or equipment.

F. Nondestructive examination of welds will be conducted at Owner's direction using radiography. Acceptable welds will not display any imperfections as indicated in Table 136.41 of Power Piping Code B31.1-1986.

G. Screwed Joints. Make up all threaded joints using a suitable joint lubricating compound applied to male threads only. Thoroughly ream all field cuts and carefully make all connections so that thread engagement will be secured.

H. Flanged Joints.

1. Prior to installation of bolts, accurately center and align flanged joints to prevent mechanical prestressing of flanges, pipe and equipment. Align bolt holes to straddle the vertical, horizontal or north-south center line. Do not exceed 3/64 inch per foot inclination of the flange face from true alignment.

2. Install proper gaskets, suitable for intended service and factory cut to proper dimensions. Secure with a suitable gasket cement.

3. Tighten bolts progressively to prevent unbalanced stress. Draw bolts tight to ensure proper seating of gaskets.

4. Take special care when attaching suction and discharge piping to pumping equipment to ensure that no stresses are transmitted to or imposed on pump suction and discharge flanges by connected piping. Install and permanently support all such piping to accurately match bolt holes and to provide uniform contact over entire installation of bolts in flanges. In addition, pump connection piping shall be free to move parallel to its longitudinal center line while bolts in pump connection flanges are tightened.

3.4 OFFSETS AND FITTINGS

A. Because of the small scale of drawings, the indication of all offsets and fittings is not possible. Carefully investigate the structural and finish conditions affecting the work and take such steps as may be required to meet such conditions.

B. Install all piping close to walls, ceilings and columns so piping will occupy the minimum space. Provide proper space for covering and removal of pipe, special clearances, and for offsets and fittings.


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3.5 ANCHORS

Provide anchors as indicated or required. Use pipe anchors consisting of heavy steel collars with lugs and bolts for clamping to pipe and attaching anchor braces. Install anchor braces in the most effective manner to secure desired results. Do not install supports, anchors or similar devices where they will damage construction during installation or because of the weight or the expansion of the pipe.

3.6 PIPE SLEEVES

A. Fit all pipes passing through masonry and concrete construction with sleeves of galvanized steel pipe. Size sleeve for minimum clearance between pipe or insulation and sleeve.

B. Extend each sleeve through the floor or wall. Cut the sleeve flush with each surface, except that in exposed locations, extend floor sleeves 3 inches above finished floor line.

C. Caulk all sleeves water and airtight. Seal annular space between pipes and sleeves with firestopping compound.

3.7 PIPE GUIDES

A. Guide expansion joints with two guides on the side opposite the anchor.

B. Guide pipe installed and supported by Unistrut supports using a duplicate set of pipe rolls on the top of the pipe.

C. Guide piping in vertical chases at a maximum guide spacing of 15 feet.

3.8 CLEANING OF PIPING SYSTEMS

A. Clean piping systems thoroughly. Purge pipe of construction debris and contamination before placing the systems in service. Provide whatever temporary connections are required for cleaning, purging and circulating.

B. Install temporary strainers in front of pumps, tanks, water still, solenoid valves, control valves, and other equipment where permanent strainers are not indicated. Keep these strainers in service until the equipment has been tested, then remove either entire strainer or straining element only. Fit strainers with a line size blowoff valve.

C. Circulate a chemical cleaner in chilled, heating and condensing water as well as steam and condensate piping systems to remove mill scale, grease, oil and silt. Circulate Betz Entec 323 detergent with Betz Entec 234 anti-foam compound. Circulate for 48 hours, flush system and replace with clean water. Dispose of chemical solution in accordance with local codes. The chilled and heating water system should then be treated with Betz Entec 338, nitride borate, 350 ppm as nitride with MBP inhibitor.

D. Special cleaning requirements, if any, are specified in the sections on each type of piping.

3.9 LEAK TESTS

A. All piping systems shall demonstrate leak tightness. This requirement shall be met by a water hydrostatic leak test or a pneumatic leak test, whichever is specified.

B. Liquid Piping Systems.

1. Test Preparation. Expansion joints shall be provided with temporary restraint, if required, for the additional pressure load under test or shall be isolated from the test. Equipment which is not to be subject to the pressure test shall be either disconnected from the piping or isolated by a blank flange or similar means.

2. Test Pressure. The water hydrostatic test pressure shall be in conformance with Specification Section 02515. The pressure test shall be maintained for sufficient time to inspect all joints.


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C. Special requirements, if any, for each system are specified in the section on that system.

3.10 CONNECTIONS TO EQUIPMENT FURNISHED BY OTHERS

Provide service connections to items of equipment furnished by others, utilizing equipment shop drawings furnished for indicating the exact number and location of connection points. Such final shop drawings may indicate adjustments in total number and exact location of rough-in points and in equipment dimensions. Making adjustments to field conditions is considered a part of the work required.

A. Roughing-In. When roughing-in, extend service piping to various items of equipment. Temporarily terminate at proper points as indicated on detailed equipment shop drawings or as directed. Do not use contract drawings accompanying these specifications for rough-in locations but only for pipe sizing and general routing.

B. Final Connections. Provide all standard items such as pipe, fittings, adapters, insulation, and other plumbing materials required to connect from rough-in locations to service fixtures and associated apparatus, including necessary stop valves and P-traps.

C. Stop Valves. Provide stop valves for each service at rough-in locations, except for drains. Stop valve locations are subject to approval, and in all cases must be accessible from the same room in which the furniture or equipment is located.

END OF SECTION


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BLANK PAGE


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DUCTILE IRON PIPE AND FITTINGS 015106-1

SECTION 15106

DUCTILE IRON PIPE AND FITTINGS

PART 1 - GENERAL


A. Ductile iron pipe and fittings for water lines, wastewater force mains, gravity sanitary sewers, and storm sewers.

1.2 RELATED WORK


B. Testing Piping Systems. Section 15032.

C. Polyethylene Encasement/Wrap. Section 02528.

D. Pipe and Pipe Fittings. Section 15105.

1.3 REFERENCES

A. ANSI A 21.4 (AWWA C 104) - Standard for Cement-Mortar Lining for Ductile-Iron Pipe and Fittings, for Water.

B. ANSI A 21.10 (AWWA C 110) - Standard for Ductile-Iron and Gray-Iron Fittings, 3-in. through 48-in.

C. ANSI A 21.11 (AWWA C 111) - Standard for Rubber Gasket Joints for Ductile-Iron Pressure Pipe and Fittings.

D. ANSI A 21.15 (AWWA C 115) - Standard for Flanged Ductile-Iron Pipe With Ductile-Iron or Gray-Iron Threaded Flanges.

E. ANSI A21.16 (AWWA C 116) - Protective Fusion Bonded Epoxy Coating for the Interior and Exterior Surfaces of Ductile Iron and Grey iron Fittings for Water Supply Service.

F. ANSI A 21.50 (AWWA C 150) - Standard for Thickness Design of Ductile-Iron Pipe.

G. ANSI A 21.51 (AWWA C 151) - Standard for Ductile-Iron Pipe, Centrifugally Cast, for Water and Other Liquids.

H. ANSI A 21.53 (AWWA C 153) - Standard for Ductile Iron Compact Fittings, 3 inches through 24 inches and 54 inches through 64 inches for Water Service.

I. ASME B 16.1 - Cast Iron Pipe Flanges and Flanged Fittings.

J. ASTM D 1248 - Standard Specification Polyethylene Plastics Molding and Extrusion Materials for Wire and Cable.

K. ASTM F 477 - Elastomeric Seals (gaskets) for Joining Plastic Pipe.

L. ASTM G 62 - Standard Test Methods for Holiday Detection in Pipeline Coatings.

M. AWWA C 105 - Polyethylene Encasement for Ductile-Iron Pipe Systems.

N. AWWA C 300 - Standard for Prestressed Concrete Pressure Pipe, Steel-Cylinder Type, for Water and other Liquids.

O. AWWA C 600 - Standard for Installation of Ductile-Iron Water Mains and Their Appurtenances.


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P. SSPC-SP 6 - Steel Structures Painting Council, Commercial Blast Cleaning.

Q. American Railway Engineering and Maintenance-of-Way Association (AREMA) Manual for Railway Engineering.

R. American Association of State Highway Transportation Officials (AASHTO).

1.4 SUBMITTALS


B. For pipe 16 inches and greater submit shop drawings signed and sealed by Professional Engineer registered in State of Texas showing the following:

1. Manufacturer's pipe design calculations.

2. Provide lay schedule of pictorial nature indicating alignment and grade, laying dimensions, fitting, flange, and special details, with plan view of each pipe segment sketched, detailing pipe invert elevations, horizontal bends, restrained joints, and other critical features. Indicate station numbers for pipe and fittings corresponding to Drawings. Do not start production of pipe and fittings prior to review and approval by Owner’s Representative. Provide final approved lay schedule on CD-ROM in Adobe portable document format (*.PDF).

3. Calculations and limits of thrust restraint.

4. Class and length of joint.

C. Submit manufacturer's certifications that ductile iron pipe and fittings meet provisions of this Section and have been hydrostatically tested at factory and meet requirements of ANSI A 21.51.

D. Submit certifications that pipe joints have been tested and meet requirements of ANSI A 21.11.

E. Submit affidavit of compliance in accordance with ANSI A21.16 for fittings with fusion bonded epoxy coatings or linings.

PART 2 - PRODUCTS

2.1 DUCTILE IRON PIPE

A. Ductile Iron Pipe Barrels: Shall conform to AWWA C115, C150 and C151 and bear mark of Underwriters’ Laboratories approval. Unless otherwise shown on Drawings, provide the following minimum pressure/thickness classes:


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1. Flanged Pipe:

a) Minimum Thickness Class 53.

2. Push-on and Mechanical Joint Pipe:

a) 12-inch and smaller: Class 350.

b) 14-inch through 20-inch: Class 250.

c) 24-inch: Class 200.

d) 30-inch and larger: Class 150.

B. Provide pipe sections in standard lengths, not less than 18 feet long, except for special fittings and closure sections as indicated on shop drawings.

C. In lieu of furnishing ductile iron pipe with cathodic protection system, furnish ductile iron pipe with polyethylene encasement in accordance with Section 2528 - Polyethylene Encasement/Wrap, provided the following criteria is met:

1. Provide minimum thickness class.

2. Provide polyethylene encasement material and installation in accordance with AWWA C105, and backfill as specified. Minimum of two complete wraps of 8-mil-thick polyethylene.

3. Use polyethylene encasement for open cut installations only. For augered sections or sections installed inside a casing, provide coating in accordance with paragraph 2.05 D.1.

4. Adhere to other requirements specified herein (e.g., insulation kits, etc.).

D. For use of pressure class pipe for water lines, design pipe and fittings to withstand most critical simultaneous application of external loads and internal pressures. Base design on minimum of AASHTO HS-20 loading, AREMA E-80 loads and depths of bury as indicated on Drawings. Design pipes with Marston's earth loads for a transition width trench for zero to 16 feet of cover. Use Marston's earth loads for a trench width of O.D. (of pipe) + 4 feet for pipe greater than 16 feet of cover. Use Marston's equations for a trench condition in both open-cut and tunnel applications. Design for most critical groundwater level condition. Pipe design conditions:

1. Working pressure = 100 psi.

2. Hydrostatic field test pressure = 150 psi.

3. Maximum pressure due to surge = 150 psi.

4. Minimum Pressure due to surge = -10 psi.

5. Design tensile stress due to surge or hydrostatic test pressure: No greater than 50% minimum yield.

6. Design bending stress due to combined earth loads and surge or hydrostatic test pressure: No greater than 48,000 psi.

7. Unit weight of fill ∃ 120 pcf.

8. Deflection lag factor (Dl) = 1.2.


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9. Bedding constant (K) = 0.1.

10. Moment coefficient = 0.16.

11. Fully saturated soil conditions hw=h=depth of cover above top of pipe.

E. Hydrostatic Test of Pipe: AWWA C 151, Section 5.2.1, at point of manufacture. Hold test for a minimum 2 minutes for thorough inspection of pipe. Repair or reject pipe revealing leaks or cracks.

F. Pipe Manufacturer for large diameter water lines: Minimum of 5 years of successful pipe installations in continuous service. Manufacturer must maintain on site or in plant enough fittings to satisfy the following requirements:

Line Diameter Required Bends

20 and 24 inches Four 45Ε bends per 5,000 LF of water line

> 24 inches Four 22.5Ε bends per 10,000 LF of water line

*Based on total length of contract (minimum of four). Any combination of bends may be substituted at manufacturer's option (i.e. two 22.5Ε bends are equivalent to one 45Ε bend) and will be counted as one fitting.

Manufacturer or supplier must be capable of delivering bends to job site within 12 hours of notification. Use fittings at direction of Owner’s Representative where unforeseen obstacles are encountered during construction. These fittings are in addition to any fittings called out in construction documents and must be available at all times.

G. Provide flange adapter with insulating kit as required when connecting new piping to existing piping and piping of different materials, unless otherwise approved by Owner’s Representative.

H. Clearly mark pipe section to show location and thickness/pressure class color coded.

I. No welding will be permitted on Ductile Iron Pipe except at restrained joint spigots. No field welding is allowed.

2.2 JOINTS

A. Joint Types: ANSI A 21.11 push-on; ANSI A 21.11 mechanical joint; or ANSI A 21.16 flanged end. Provide push-on joints unless otherwise indicated on the Drawings or required by these specifications. For bolted joints, conform to requirements of AWWA C111; provide minimum 304 stainless steel for restrained joints.

B. Where required by Drawings, provide approved restrained joints for buried service. Provide Megalug Series 1100 Mechanic Joint Restraint manufactured by EBAA Iron, Inc., or approved equal.

C. Threaded or grooved-type joints which reduce pipe wall thickness below minimum required are not acceptable.


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D. Provide for restrained joints designed to meet test pressures required under Section 02515 – Hydrostatic Testing of Pipelines as applicable. Provide restrained joints for test pressure or maximum surge pressure as specified, whichever is greater for water lines. Do not use passive resistance of soil in determining minimum restraint lengths.

E. Make curves and bends by deflecting joints. Do not exceed maximum deflection recommended by pipe manufacturer for pipe joints or restraint joints. Submit details of other methods of providing curves and bends for consideration by Owner’s Representative. When other methods are deemed satisfactory, install at no additional cost to City.

2.3 GASKETS

A. Furnish, when no contaminant is identified, plain rubber (SBR) gasket material in accordance with ANSI A21.11 or ASTM F 477 (One Bolt only); for flanged joints 1/8-inch-thick gasket in accordance with ANSI A 21.15.

B. For Pipes to be installed in any contaminated areas, use gaskets as recommended by the Pipe Manufacturer, Engineer of the Record and approved by City Engineer prior to installation.

2.4 FITTINGS

A. Use fittings of same size as pipe. Reducers are not permitted to facilitate an off-size fitting. Reducing bushings are also prohibited. Make reductions in piping size by reducing fittings. Line and coat fittings as specified for pipe they connect to.

B. Push-on Fittings: ANSI A 21.10; ductile iron ANSI A 21.11 joints, gaskets, and lubricants; pressure rated at 250 psig.

C. Flanged Fittings: ANSI 21.10; ductile iron ANSI A 21.11 joints, gaskets, and lubricants; pressure rated at 250 psig.

D. Mechanical Joint Fittings: ANSI A 21.11; pressure rated at 250 psi.

E. Ductile Iron Compact Fittings: Shall conform to AWWA C153 and shall be:

1. Fusion bonded epoxy lined or

2. Cement mortar lined.

F. For tangential flanged outlets shown on Drawings, substitute with a tee with an equivalent sized outlet unless otherwise approved by Owner’s Representative.

2.5 COATINGS AND LININGS

A. Water line Interiors: ANSI A21.4, cement lined with seal coat; ANSI A 21.16 fusion bonded epoxy coating for interior; comply with NSF 61.

B. Sanitary Sewer and Force Main Interiors:

1. Preparation: Commercial blast cleaning conforming to SSPC-SP6.

2. Liner thickness: Nominal 40 mils, for pipe barrel interior; minimum 6 to 10 mils at gasket groove and outside spigot end to 6-inches back from end.

3. Testing: ASTM G 62, Method B for voids and holidays; provide written certification.


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4. Acceptable Lining Materials:

a) Provide approved virgin polyethylene conforming to ASTM D 1248, with inert fillers and carbon black to resist ultraviolet degradation during storage; heat bonded to interior surface of pipe and fittings.

b) Ceramic Epoxy – Protecto 401 or approved equal.

C. Sanitary Sewer Point Repair Pipe: For pipes which will be lined with high density polyethylene liner pipe or cured-in-place liner, provide cement-lined with seal coat in accordance with ANSI A 21.4. For pipes which will not be provided with named liner, provide pipe as specified in Paragraph 2.05B, Sanitary Sewer and Force Main Interiors.

D. Exterior:

1. Encasement and coating requirement for water lines

a) Open cut construction method: i. Provide double wrap polyethylene encasement applied in

accordance with AWWA C105 in accordance with Section 02528 – Polyethylene Encasement/Wrap

2. Sanitary Sewers: Prime coat and outside asphaltic coating conforming to ANSI A21.10, ANSI A21.15, or ANSI A21.51 for pipe and fittings in open cut excavation and in casings.

E. Polyethylene Wrap: For buried pipes not cathodically protected, provide polyethylene wrap unless otherwise specified or shown. Conform to requirements of Section 02528 - Polyethylene Encasement/Wrap.

F. For flanged joints in buried service, provide petrolatum wrapping system, Denso, or equal, for the complete joint and alloy steel fasteners. Alternatively, provide bolts made of Type 304 stainless steel.

G. Pipe to be installed in potentially contaminated areas shall have coatings and linings recommended by the manufacturer for maximum resistance to the contaminants identified in the Phase II Environmental Site Assessment Report.

2.6 MANUFACTURERS

A. American Cast Iron Pipe Co. (American)

B. U.S. Pipe Co.

C. Clow Water System Co.

PART 3 - EXECUTION

3.1 PREPARATION

A. Conform to applicable manufacturer installation specifications.

B. Employ workmen who are skilled and experienced in laying pipe of type and joint configuration being furnished. Provide watertight pipe and pipe joints.

C. Lay pipe to lines and grades shown on Drawings.


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D. Confirm that nine (9) feet minimum separation from gravity sanitary sewers and manholes or separation of four (4) feet minimum from force mains as specified in this Section in all directions unless special design is provided on Drawings.

E. Where above clearances cannot be attained, and special design has not been provided on Drawings, obtain direction from Owner’s Representative before proceeding with construction.

F. Inform Owner’s Representative if unmetered sprinkler or fire line connections exist which are not shown on Drawings. Make transfer only after approval by Owner’s Representative.

G. For projects involving multiple subdivisions or locations, limit water line installation to maximum of two project site locations. Maximizing two (2) pipe installation crews shall be permitted, unless otherwise approved by Owner’s Representative.

H. City of Conroe will handle, at no cost to Contractor, operations involving opening and closing valves for wet connections and for chlorination. Contractor is responsible for handling necessary installations and removal of chlorination and testing taps and risers.

I. If asbestos-cement (A.C.) pipe is encountered, follow safety practices outlined in American Water Works Association's publication, "Work Practices for A/C Pipe". Strictly adhere to "recommended practices" contained in this publication and make them "mandatory practices" for this Project.

J. For pipe diameters 36 inches and greater, clearly mark each section of pipe and fitting with unique designation on inside of pipe along with pressure class. Locate unique identifying mark minimum of five feet away from either end of each section of pipe. Provide one unique identifying mark in middle of each fitting. Place markings at consistent locations. Use permanent black paint and minimum letter height of 4 inches to mark designations.

K. Contractor is responsible for assuring chosen manufacturer fulfills requirements for extra fittings and, therefore, is responsible for costs due to downtime if requirements are not met.

L. Do not remove plugs or clamps during months of peak water demands; June, July and August, unless otherwise approved by Owner or Owner’s Representative.

3.2 HANDLING, CLEANING AND INSPECTION

A. Handling:

1. Place pipe along project site where storm water or other water will not enter or pass through pipe.

2. Load, transport, unload, and otherwise handle pipe and fittings to prevent damage of any kind. Handle and transport pipe with equipment designed, constructed and arranged to prevent damage to pipe, lining and coating. Do not permit bare chains, hooks, metal bars, or narrow skids or cradles to come in contact with coatings. Where required, provide pipe fittings with sufficient interior strutting or cross bracing to prevent deflection under their own weight.

3. Hoist pipe from trench side into trench by means of sling of smooth steel cable, canvas, leather, nylon or similar material.


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4. For large diameter water lines, handle pipe only by means of sling of canvas, leather, nylon, or similar material. Sling shall be minimum 36 inches in width. Do not tear or wrinkle tape layers.

5. Use precautions to prevent injury to pipe, protective linings and coatings.

a) Package stacked pipe on timbers. Place protective pads under banding straps at time of packaging.

b) Pad fork trucks with carpet or other suitable material. Use nylon straps around pipe for lift when relocating pipe with crane or backhoe.

c) Do not lift pipe using hooks at each end of pipe. d) Do not place debris, tools, clothing, or other materials on pipe.

6. Repair damage to pipe or protective lining and coating before final acceptance.

7. Reject pipe with visible cracks (not meeting exceptions) and remove from project site.

B. Cleaning: Thoroughly clean and dry interior of pipe and fittings of foreign matter before installation, and keep interior clean until Work has been accepted. Keep joint contact surfaces clean until jointing is completed. Do not place debris, tools, clothing or other materials in pipe. After pipe laying and joining operations are completed, clean inside of pipe and remove debris.

C. Inspection: Before installation, inspect each pipe and fitting for defects. Reject defective, damaged or unsound pipe and fittings and remove them from site.

3.3 EARTHWORK

A. Conform to applicable provisions of Section 02223 – Earthwork and Section 02315 - Excavation Trenching and Backfilling for Utilities.

B. Bedding: Use bedding materials in conformance with Section 02223 – Earthwork and Section 02315 - Excavation Trenching and Backfilling for Utilities.

C. Backfill: Use bank run sand or earth or native soil as specified in Section 02223 – Earthwork. Backfill excavated areas in same day excavated. When not possible, cover excavated areas using steel plates on paved areas and other protective measures elsewhere.

D. Place material in uniform layers of prescribed maximum loose thickness and wet or dry material to approximately optimum moisture content. Compact to prescribed density Water tamping is not allowed.

E. Pipe Embedment: Including 6-inch pipe bedding and backfill to 12 inches above top of pipe.

3.4 PIPE CUTTING

A. Cut pipe 12 inches and smaller with standard wheel pipe cutters. Cut pipe larger than 12 inches in manner approved by Owner’s Representative. Make cuts smooth and at right angles to axis of pipe. Bevel plain end with heavy file or grinder to remove sharp edges.


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3.5 BURIED PIPING INSTALLATION

A. Install in accordance with AWWA C 600 and manufacturer's recommendations.

B. General Requirements:

1. Lay pipe in subgrade free of water.

2. Make adjustments of pipe to line and grade by scraping away subgrade or filling in with granular material.

3. Properly form bedding to fully support bell without wedging or blocking up bell.

4. Open Cut Construction: Keep pipe trenches free of water which might impair pipe laying operations. Grade trench to provide uniform support along bottom of pipe. Excavate for bell holes after bottom has been graded and in advance of placing pipe. Lay not more than nominal city block length of not more than 300 feet of pipe in trench ahead of backfilling operations. Cover or backfill laid pipe if pipe laying operations are interrupted and during non-working hours. Place backfill carefully and simultaneously on each side of pipe to avoid lateral displacement of pipe and damage to joints. If adjustment of pipe is required after it has been laid, remove and re-lay as new pipe.

C. Install pipe continuously and uninterrupted along each street on which work is to be performed. Obtain approval of Owner’s Representative prior to skipping any portion of Work.

D. Protection of Pipeline: Securely place stoppers or bulkheads in openings and in end of line when construction is stopped temporarily and at end of each day's work.

E. Laying Large Diameter Water Line

1. Lay not more than 50 feet of pipe in trench ahead of backfilling operations.

2. Dig trench proper width as shown. When trench width below top of pipe becomes 4 feet wider than specified, install higher class of pipe or improved bedding, as determined by Owner’s Representative. No additional payment will be made for higher class of pipe or improved bedding.

3. Use adequate surveying methods and equipment; employ personnel competent in use of this equipment. Horizontal and vertical deviations from alignment as indicated on Drawings shall not exceed 0.10 feet. Measure and record "as-built" horizontal alignment and vertical grade at maximum of every 100 feet on record drawings.

4. Prevent damage to coating when placing backfill. Use backfill material free of large rocks or stones, or other material which could damage coatings.

5. Before assembling couplings, lightly coat pipe ends and outside of gaskets with cup grease or liquid vegetable soap to facilitate installation.

6. Prior to proceeding with critical tie-ins submit sequence of work based on findings from "critical location" effort.


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F. Perform following additional procedures when working on plant sites.

1. Seventy-two (72) hours prior to each plant shut down or connection, schedule coordination meeting with Owner’s Representative and Water Production personnel. At this meeting, present proposed sequencing of Work and verification of readiness to complete Work as required and within time permitted. Do not proceed with Work until Owner’s Representative agrees key personnel, equipment and materials are on hand to complete Work.

2. Prior to fully excavating around existing piping, excavate as minimal as possible to confirm type and condition of existing joints. Verify size, type, and condition of pipe prior to ordering materials or fully mobilizing for Work.

3. Do not proceed with connections to existing piping and identified critical stages of work unless approved by Owner’s Representative and City Representative is present to observe.

4. Coordinate with City operators to obtain reduction in operating pressures prior to performing connections to existing piping.

5. Make connections to existing piping only when two valves are closed off between connection and source of water pressure. Do not make connection relying solely on one valve, unless otherwise approved by Owner’s Representative.

6. Perform critical stages of Work identified on Drawings at night or during low water demand months as specified in Section 01010 - Summary of Work.

7. Excavation equipment used on plant sites to have smooth bucket; no teeth or side cutters.

8. Submit to Owner’s Representative Lone Star Notification transmittal number prior to beginning excavation.

9. Before each "dig" with mechanical excavator, probe ground to determine potential obstructions. Repeat procedure until existing pipe is located or excavation reaches desired elevation. Perform excavations within one foot to existing piping by hand methods.

10. Provide adequate notice to pipe manufacturer’s representative when connecting or modifying existing prestressed or pretensioned concrete cylinder pipe.

11. Provide field surveyed (horizontal and vertical elevations) "as-builts" of new construction and existing underground utilities encountered. Submit in accordance with Section 01330 - Submittal Procedures.

12. Prior to performing plant work to be done on weekend, provide list of sites and contact person with phone numbers to Owner’s Representative by noon on Thursday of week. Contact person must be accessible during weekend, have Houston Metro Area phone number, and be authorized to make emergency decisions.

13. No night work or plant shut down will be scheduled to begin two (2) working days before or after designated City Holidays.


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G. For tie-ins to existing water lines, provide necessary material on hand to facilitate connection prior to shutting down existing water line. Provide City a minimum of two (2) weeks’ notice prior to shutting down existing water line.

3.6 JOINTS AND JOINTING

A. Rubber Gasketed Bell-and-Spigot Joints.

1. After rubber gasket is placed in spigot groove of pipe, equalize rubber gasket cross section by inserting tool or bar recommended by manufacturer under rubber gasket and moving it around periphery of pipe spigot.

2. Lubricate gaskets with nontoxic water-soluble lubricant before pipe units are joined.

3. Fit pipe units together in manner to avoid twisting or otherwise displacing or damaging rubber gasket.

4. After pipe sections are joined, check gaskets to ensure that no displacement of gasket has occurred. If displacement has occurred, remove pipe section and remake joint as for new pipe. Remove old gasket, inspect for damage and replace if necessary before remaking joint.

5. Where preventing movement of 16-inch diameter or greater pipe is necessary due to thrust, use restrained joints as shown on Drawings.

a) Include buoyancy conditions for soil unit weight when computing thrust restraint calculations.

b) Do not include passive resistance of soil in thrust restraint calculations.

6. Provide means to prevent full engagement of spigot into bell as shown on Drawings. Means may consist of wedges or other types of stops as approved by Owner’s Representative.

7. Use feeler gauge to verify water-tightness of each pipe joint prior to application of joint grout. Perform feeler gauge test from interior of pipe, immediately after installation and after backfilling and compaction. Perform feeler gauge test in accordance with manufacturer’s recommendations to determine if the joint is within tolerance. Provide results to Owner’s Representative. Notify Owner’s Representative immediately when a joint is found to be out of tolerance or fails feeler gauge test, and submit repair plan for approval by Owner’s Representative.

B. Flanged Joints

1. AWWA C 207. Prior to installation of bolts, accurately center and align flanged joints to prevent mechanical prestressing of flanges, pipe and equipment. Align bolt holes to straddle vertical, horizontal or north-south center line. Do not exceed 3/64 inch per foot inclination of flange face from true alignment.

2. Use full-face gaskets for flanged joints. Provide 1/8-inch-thick cloth inserted rubber gasket material. Cut gaskets at factory to proper dimensions.


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3. Use galvanized or black nuts and bolts to match flange material. Use cadmium-plated steel nuts and bolts underground. Tighten bolts progressively to prevent unbalanced stress. Maintain at all times approximately same distance between two flanges at points around flanges. Tighten bolts alternately (180° apart) until all are evenly tight. Draw bolts tight to ensure proper seating of gaskets. Provide Densco petroleum based tape or approved equal for all exposed portions of nuts, bolts and pipe.

4. Full length bolt isolating sleeves and washers shall be used with flanged connections. Furnish kits in accordance with City's "Approved Products List."

5. For in-line flange joints 30 inches in diameter and greater and at butterfly valve flanges, provide Pyrox G-10 with nitrite seal, conforming to ANSI A 21.11 mechanical joint gaskets. For in-line flange joints sized between 12 inches in diameter and greater and 24 inches in diameter and smaller, provide Phenolic PSI with nitrite seal gasket conforming to ANSI A 21.11 mechanical joint gaskets.

C. Restrained Joints

1. When connecting to existing water lines, provide concrete thrust blocks for restraint.

2. Thrust restraint lengths shown on Drawings are minimum anticipated lengths. These lengths are based on deflections indicated and on use of prestressed concrete cylinder pipe for large diameter lines and ductile iron pipe for small diameter lines. Adjustments in deflections or use of other pipe material may result in reduction or increase of thrust lengths. Perform calculations by pipe manufacturer to verify proposed thrust restraint lengths. Submit calculations for all pipe materials sealed by a registered Professional Engineer in State of Texas for review by Owner’s Representative. Make adjustments in thrust restraint lengths at no additional cost to City.

3. Passive resistance of soil will not be permitted in calculation of thrust restraint.

4. For 16-inch lines and larger use minimum 16-foot length of pipe in and out of joints made up of beveled pipe where restraint joint lengths are not identified on Drawings. Otherwise, provide restraint joints for a minimum length of 16 feet on each side of beveled joints.

5. Installation.

a) Install restrained joints mechanism in accordance with manufacturer's recommendations.

b) Examine and clean mechanism; remove dirt, debris and other foreign material.

c) Apply gasket and joint NSF 61 FDA food grade approved lubricant. d) Verify gasket is evenly seated. e) Do not over stab pipe into mechanism.

6. Prevent any lateral movement of thrust restraints throughout pressure testing and operation.


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7. Place 2,500 psi concrete conforming to Section 03305 – Incidental Concrete, for blocking at each change in direction of existing water lines, to brace pipe against undisturbed trench walls. Finish placement of concrete blocking, made from Type I cement, 4 days prior to hydrostatic testing of pipeline. Test may be made two (2) days after completion of blocking if Type II cement is used.

D. Large Diameter Water Main Joint Testing: In addition to testing individual joints with feeler gauge approximately 1/2 inch wide and 0.015-inch thick, use other joint testing procedure approved or recommended by pipe manufacturer which will help ensure watertight installation prior to backfilling. Perform tests at no additional cost to City.

E. Make curves and bends by deflecting joints or other method as recommended by manufacturer and approved by Owner’s Representative. Submit details of other methods of providing curves and bends which exceed manufacturer's recommended deflection prior to installation.

1. Deflection of pipe joints shall not exceed maximum deflection recommended by pipe manufacturer, unless otherwise indicated on Drawings.

2. If deflection exceeds that specified but is less than five (5) percent, repair entire deflected pipe section such that maximum deflection allowed is not exceeded.

3. If deflection is equal to or exceeds five (5) percent from that specified, remove entire portion of deflected pipe section and install new pipe.

4. Replace, repair, or reapply coatings and linings as required.

5. Assessment of deflection may be measured by Owner’s Representative at location along pipe. Arithmetical averages of deflection or similar average measurement methods will not be deemed as meeting intent of standard.

6. When rubber gasketed pipe is laid on curve, join pipe in straight alignment and then deflect to curved alignment.

3.7 CATHODIC PROTECTION APPURTENANCES

A. Where identified on Drawings, modify pipe for cathodic protection as detailed on Drawings and specified. Unless otherwise noted, provide insulation kits including test stations at connections to existing water system or at locations to isolate one type of cathodic system from another type, between water line, access manhole piping and other major openings in water line, or as shown on Drawings.

B. Bond joints for pipe installed in tunnel or open cut, except where insulating flanges are provided. Weld strap or clip between bell and spigot of each joint or as shown on Drawings. No additional bonding required where joints are welded for thrust restraint. Repair coatings as specified by appropriate AWWA standard, as recommended by manufacturer, and as approved by Owner’s Representative.

C. Bonding Strap or Clip: Free of foreign material that may increase contact resistance between wire and strap or clip.

3.8 SECURING, SUPPORTING AND ANCHORING

A. Support piping as shown on Drawings and as specified in this Section, to maintain line and grade and prevent transfer of stress to adjacent structures.


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B. Where shown on Drawings, anchor pipe fittings and bends installed on water line by welding consecutive joints of pipe together to distance each side of fitting. Restrained length, as shown on Drawings, assumes that installation of pipe and subsequent hydrostatic testing begins upstream and proceed downstream, with respect to normal flow of water in pipe. If installation and testing differs from this assumption, submit for approval revised method of restraining pipe joints upstream and downstream of device used to test against (block valve, blind flange or dished head plug).

C. Use adequate temporary blocking of fittings when making connections to distribution system and during hydrostatic tests. Use sufficient anchorage and blocking to resist stresses and forces encountered while tapping existing water line.

3.9 POLYETHYLENE WRAP FOR DUCTILE IRON PIPE

A. Double wrap pipe and appurtenances (except fire hydrants and fusion bond or polyurethane coated fittings) with 8-mil polyethylene film.

B. Conform to requirements of Section 02528 - Polyethylene Encasement/Wrap.

3.10 CLEANUP AND RESTORATION

A. Provide cleanup and restoration crews to work closely behind pipe laying crews, and where necessary, during disinfection and hydrostatic testing, service transfers, abandonment of old water lines, backfill and surface restoration.

B. Unless otherwise approved by Owner’s Representative, comply with the following:

1. Once water line is installed to limits approved in layout submitted, immediately begin preparatory work for disinfection effort.

2. No later than three days after completing disinfection preparatory work, submit to City appropriate request for disinfection.

3. If City fails to perform initial disinfection of lines in accordance with Section 02675 – Cleaning and Disinfection of Water Piping, Equipment and Facilities, within seven (7) days from submission of appropriate request, and if approved by Owner’s Representative, pipe laying operations may continue beyond approved limits until the City responds.

4. Immediately after transfer of services, begin abandonment of old water lines and site restoration.

5. Do not exceed a total of 50% of total project linear feet of disturbed right-of-way and easement until site is restored in accordance with Section 01500 – Construction Facilities and Temporary Controls.

6. Exceeding any of the above footage limitations shall be considered a material breach of the Contract and subject to termination in accordance with the General Conditions.

C. For large diameter water lines, do not install more than 2,000 linear feet of water line, without previous 2,000 linear feet being restored in accordance with Section 01500 – Construction Facilities and Temporary Controls. Schedule paving crews so repaving work will not lag behind pipe laying work by more than 1,000 linear feet. Failure to comply with this requirement shall be considered a material breach of the Contract and subject to termination in accordance with the General Conditions.


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3.11 CLEANING PIPING SYSTEMS

A. Conform to requirements of Section 02675 – Cleaning and Disinfection of Water Piping, Equipment and Facilities.

B. Remove construction debris or foreign material and thoroughly broom clean and flush piping systems. Provide temporary connections, equipment and labor for cleaning. City must inspect water line for cleanliness prior to filling.

3.12 DISINFECTION OF WATER LINES

A. Conform to requirements of Section 02675 – Cleaning and Disinfection of Water Piping, Equipment and Facilities.

3.13 FIELD HYDROSTATIC TESTS

A. Conform to requirements of Section 02515 - Hydrostatic Testing of Pipelines.

END OF SECTION


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BLANK PAGE


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SUPPORTS AND ANCHORS 15140-1

SECTION 15140

SUPPORTS AND ANCHORS

PART 1 GENERAL


A. Scope: Design, furnish and install all hangers, supports, anchors, restraints, clamps and appurtenances, sleeves, collars and flashing for all piping systems and operational as shown, specified and as required.

B. This Section includes all hangers, supports, anchors, restraints, clamps and appurtenances for all piping systems, equipment bases and supports required for the work unless otherwise specified under other Sections or shown on the Drawings. In general, standard prefabricated hangers and supports are applicable to the piping system of 18" diameter or less and special support structures and hangers shall be provided as designed, shown or specified for the piping system 18" diameter and larger.

C. Piping Systems: Work includes hangers, supports, anchors, restraints and appurtenances for following systems:

1. Process piping

2. Potable water piping

3. Plumbing piping

4. Chemical piping

5. Stainless piping

6. HVAC Systems and steam heating piping.

7. Other miscellaneous piping and ductwork.

D. Support Types and Appurtenances:

1. Pipe, and equipment hangers, bases, supports, associated anchors, and restraints.

2. Equipment bases and supports.

3. Sleeves and seals.

4. Flashing and sealing equipment and pipe stacks.

5. Support inserts and anchor bolts.

6. Other miscellaneous items as may be required for complete operational installation.

E. Support Locations:

1. Pipe support locations shown on the Drawings are approximate locations.

2. The Contractor shall check all dimensions shown on the Contract Drawings prior to the installation of Work and shall notify the Engineer promptly of any interferences or errors discovered and make necessary changes in the location of pipelines to avoid such interferences in a manner as reviewed by the Engineer. When any change is made, a record of the location of all pipes shall be kept by the Contractor and a copy of such record shall be given to the Engineer showing the location of all piping.


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F. Hanger type: Hanger support components shall be selected and sized to accommodate system movement and loading conditions, and shall be appropriate for the system being supported, in accordance with MSS SP-58, SP-69 and SP-89.

G. Coordination:

1. Review installation procedures under other Sections and coordinate the Work that must be installed with or attached to the hangers and supports.

2. Notify other contractors in advance of the Work to provide them with sufficient time for the installation of and coordination of items included in their contracts that must be installed in conjunction with the hangers and supports.


A. Section 05120 – Structural Steel.

B. Section 15010 – Basic Mechanical Requirements.

C. Section 15011 – Basic Mechanical Procedures & Methods.

D. Section 15105 – Pipe and Pipe Fittings.

E. Section 15106 – Ductile Iron Pipe and Fittings.

F. Section 15410 – Plumbing

1.3 REFERENCES

A. The Manufacturers Standardization Society

B. MSS SP-58, Pipe Hangers and Supports - Materials and Design.

C. MSS SP-69, Pipe Hangers and Supports - Selection and Application.

D. MSS SP-89, Pipe Hangers and Supports - Fabrication and Installation Practices

E. FS W-H-171 - Hangers and Support, Pipe - Federal Spec.

F. ASTM A575, Steel Bars, Carbon Merchant Quality, M-Grades

G. UL-203 - Pipe Hanger Equipment - Underwriters' Laboratories, Inc. Standard.

H. AISC Manual of Steel Construction - American Institute of Steel Construction - Allowable Stress Design

I. Code for Pressure Piping, ANSI B31.1


A. Source Quality Control: Obtain each type of pipe hanger or support from no more than one manufacturer.

B. Reference Standards: Comply with applicable provisions and recommendations of the above referenced standards, except as otherwise shown or specified.

1.5 SUBMITTALS

A. Shop Drawings:

1. Submit shop drawings and product data under provisions of Section 01330.

2. Submit detailed shop drawings showing all hangers, supports, anchors and restraints for all piping systems.

3. Show location, installation, material, loads and reactions at supporting structure, and deflection of all hangers, supports, anchors and restraints.


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4. No material shall be fabricated into hangers, supports or restraints without the review of the Engineer.

B. Manufacturers' Literature:

1. Submit to the Engineer manufacturers' catalogs, literature and engineering data on all hangers, supports and restraints.

2. Load ratings, materials and installation shall be consistent with the recommendations of MSS SP-58 and MSS SP-69.

PART 2 PRODUCTS

2.1 GENERAL REQUIREMENTS

A. Where conceptual designs are shown without adequate dimensions and notes, the contractor shall design and provide proper support system based on the conceptual designs indicated.

B. Supports shall be located as required, specified and/or as shown on Contract Drawings.

C. The hangers and supports shall meet with the following requirements:

1. Standard and fabricated hangers and supports shall be furnished complete with necessary inserts, bolts, nuts, rods, washers, and other accessories.

2. Material for all hangers and supports:

a. Chlorine Atmosphere: Type 316L stainless steel epoxy painted in field or fiberglass reinforced of equivalent strength.

b. Other Areas: Carbon Steel, iron, reinforced fiberglass reinforced concrete and as specified or shown. Hangers and supports in submerged, wet or damp locations such as basins, pipe galleries, vaults and basements shall be cast iron, hot-dip galvanized steel, stainless steel or plastic coated.

3. Run piping in groups where practicable and parallel to building walls generally. Where several pipes can be installed in parallel and at same elevation, provide multiple or trapeze hangers. Provide minimum clearance of three (3) inches between pipe and other work.

4. Hangers and supports shall be capable of adjustment after placement of piping. Horizontal piping hangers and supports shall allow a minimum of 1-3/4 inches vertical adjustment for pipe alignment and shall be provided with lock units. Hanger rods shall be straight and vertical.

5. Suspended or supported cast iron pipe shall have a hanger or support adjacent to each hub.

6. Vertical piping shall be supported at each floor and between floors by stays or braces to prevent rattling and vibration.

7. Chain, wire, strap, bands, tape or perforated bar hangers shall not be used. Hangers shall not be suspended from piping.

8. Maximum support spacing unless otherwise shown for plastic pipe at ambient temperature shall be one-half of the values specified for steel pipe.

9. Plastic pipe at temperature greater than 130o F shall be continuously supported in a metal cradle or tray.


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10. Where proper hanger or support spacing does not correspond with joist or rib spacing, structural steel channels may be attached to joists or ribs and pipe suspended therefrom subject to review of Engineer.

11. Prevent contact between dissimilar metals:

a. Provide isolating gaskets or couplings between dissimilar materials.

b. Use of plastic, rubber or vinyl coated hangers or supports when supporting copper tubing or bare copper or brass pipe.

c. Isolate thin walled stainless steel piping from carbon steel by using plastic coated hangers or supports or by taping at points of contact with PVC or vinyl.

d. Method utilized is subject to review of the Engineer.

12. Provide additional supports at all locations where pipe changes direction, at valves, at fittings and at equipment.

a. Place a hanger within 12 inches of each horizontal elbow and tee fitting.

b. Provide support at each valve larger than 2-inch size.

c. Provide support at each drop and/or rise to equipment connections.

d. Where changes in direction of the piping occur between pipe supports, the total length of pipe between the pipe supports shall be less than three-quarters of the maximum specified support spacing.

13. Supports shall provide adequate support both for the entire system and for the piping remaining in place when equipment and/or piping sections are removed for maintenance or cleaning.

14. Elevations and dimensions locating pipelines are shown to the centerline of the pipe on the Drawings, unless otherwise indicated.

15. Piping connections and dimensions to equipment are subject to changes as reviewed by the Engineer to suit the types of equipment furnished.

16. Piping suspended from ceilings shall be installed to provide maximum head room in compliance with applicable codes and/or regulations, and be consistent with good installation. Hangers and Supports shall be free of sharp edges, corners or projections.

17. The layout of the piping and fittings shall be carefully checked to determine that the related equipment can be properly assembled to produce a workable arrangement.

18. As soon as pipes are in place, all open ends shall be capped until permanent connections are made.

19. Horizontal runs shall be evenly pitched toward the outlet, with as steep a pitch as conditions will permit.

20. Drive screws, pins, studs, etc., or any other type of fastener of which any component contains lead, are prohibited.

21. Piping alignment guides, where indicated on the Drawings, shall be sized to accommodate thickness of insulation specified.

22. All rollers, guides, and hangers shall be shipped with a sprayed-on coating of an approved rust- preventative with an oil base.


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23. Use trapeze pipe hangers where ducts interfere with piping. There shall be at least one (1) hanger for each section of pipe.

24. Support riser piping independently of connected horizontal piping.

25. The supporting systems shall provide for, and control, the free or intended movement of the piping including its movement in relation to that of connected equipment.

26. Plant process piping supports shall meet following requirements:

a. Exposed Piping Installation shall be in accordance with specifications of pipe material.

b. Fabricate and install in accordance with more stringent of ANSI B31.1 or Specification.

c. Pipe shall be supported separately, not in tiers.

D. MAXIMUM SUPPORT SPACING for horizontal piping shall be as follows, unless otherwise shown:

1. Hard drawn copper tubing and stainless steel tubing

a. 3/4" and smaller 5'-0"

b. 1" through 1-1/4" 6'-0"

c. 1-1/2" through 2-1/2" 8'-0"

d. 3" and larger 10'-0"

2. Cast iron soil pipe:

a. All sizes 5'-0" (Located near each hub)

3. Steel pipe, Stainless Steel pipe and ductile iron pipe:

a. 3/4" through 1-1/2" 6'-0"

b. 2" and larger 10'-0"

4. Where push-on joints, mechanical joints, Dresser type, grooved type, or clamp type couplings are used, there shall be no less than two (2) supports or hangers for each section of pipe five (5) feet or more in length.

E. MAXIMUM SUPPORT SPACING for vertical piping shall be as follows:

1. Vertical piping shall be supported not more than 10'-0".

2. Unless otherwise indicated on the Drawings, vertical piping shall be supported at every floor and by means of riser clamps installed below hubs, couplings or lugs welded to the pipe.

3. On a riser subject to expansion, only one support of the rigid type shall be used.

2.2 PIPE HANGERS AND SUPPORTS

A. PIPE SUPPORT TYPES FOR VARIOUS PIPING SYSTEMS: The primary pipe supports for the various pipe services, unless otherwise specified or otherwise indicated on the Contract Drawings, shall be as follows:

1. Clevis and Rod:

a. Process Water

b. Roof Drain


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c. Potable Water

d. Chemical Feed

e. Relief valve separator drain

f. Vent

B. ROD SPRING, BASE SPRING, AND CONSTANT SUPPORTS:

1. Supports shall be sized to properly support the load imposed on the support.

2. Location of supports shown on the Drawings is subject to final arrangement of piping as installed and is subject to analysis by Contractor engaged pipe support application specialist.

3. It is intended that all piping be installed with no objectionable strain or stress on the piping system or equipment connected thereto:

a. Spring-type support shall be used where designated on Contract Drawings by final piping arrangement and where vertical pipe movement is greater than or equal to 1/8 inch.

4. Spring supports are required to support piping independent of equipment , e.g., boilers should not support pipe weight under any condition of boiler operation.

a. Maximum spring load variability shall be 20 percent.

2.3 SADDLES, CONCRETE SADDLES, BASE TEE'S, BASE ELBOWS:

See Contract Drawings

2.4 FABRICATED CONCRETE AND STEEL HANGERS, SUPPORTS AND RESTRAINTS

A. Provide fabricated concrete and steel hangers, supports and restraints and support structural steel as shown, specified and as required.

1. Materials and design shall conform to the standards of MSS SP-58.

2. Support structural steel design shall satisfy American Institute of Steel Construction (AISC) Specifications and Codes.

3. Pipes shall be supported and anchored to the fabricated pipe support, hanger and/or restraint as shown on the drawings.

B. SUPPORT STRUCTURAL STEEL: Furnish and install auxiliary structural steel for supports, which is not furnished under Section 05120.

1. Steel shall be well formed to shape and size. Shearing and punching shall leave clean, true lines and surfaces.

2. Carefully match exposed Work to produce continuity of line and design.

3. All joints, unless otherwise shown or specified, will be accurately fitted and rigidly secured with hairline contact.

4. Thickness of metal and details of assembly and support shall give adequate strength and stiffness.

C. EQUIPMENT BASES AND SUPPORTS: Provide equipment bases of poured concrete as detailed on Structural Drawings and located on piping or Mechanical Drawings:

1. Provide templates, sole plates, anchor bolts, and accessories for mounting and anchoring equipment.

2. Construct support of steel members. Brace and fasten with flanges bolted to structure.


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3. Provide rigid anchors for pipes after vibration isolation components are installed.

D. FABRICATED PIPE RACK:

1. Pipes shall be supported and anchored to the fabricated pipe rack as shown on the drawings.

2. Clamps, rollers, and supports for piping shall conform to the general requirements of MSS SP-69.

2.5 ACCESSORIES

A. Hanger rods for single rod hangers shall conform to the following:

Pipe Size Hanger Rod Diameter

2" and smaller 3/8"

2-1/2" through 3-1/2" 1/2"

4" through 5" 5/8"

6" 3/4"

8" through 12" 7/8"

14" through 18" 1"

20" through 24" 1-1/4"

Larger As indicated

B. Concrete Inserts, Expansion Anchors and Anchor Bolts:

1. Concrete inserts, expansion anchors and anchor bolts shall be in accordance with Section 05500 and as Specified hereinafter.

2. Concrete inserts shall be used for hanging pipe up to 8 inches diameter unless otherwise shown or reviewed by the Engineer.

Provide hooked rod to concrete reinforcement section for inserts.

3. Cast-in-place male ceiling anchor "J" bolts with concrete clevis plate for hanging pipe 10" through 18", unless otherwise shown or reviewed by the Engineer.

4. Hanger supports for pipe over 18 inches diameter shall be as shown on the Drawings and/or reviewed by the Engineer.

5. Expansion anchors may be used in existing ceilings for hanging pipe 8 inches diameter and smaller. Expansion anchors shall not be used for hanging vibrating equipment.

6. Expansion anchors shall be in accordance with Specifications Section 05550 – Bolts, Anchor Bolts, Expansion Anchors and Concrete Inserts.

Expansion anchors may be of the self-drilling type made of carburized and case-hardened steel.

The anchor and expansion plug shall be furnished with a rustproof finish.

These anchors shall be "Red Head" as manufactured by ITW Ramset/Red Head or approved equal.

Expansion anchors installed in areas which will be submerged shall be made of type 304 stainless steel.

Expansion anchors shall not be installed in beams or columns except as reviewed by the Engineer.


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7. Where concrete slabs form finished ceiling, provide inserts to be flush with slab surface.

8. For concrete wall fasteners and fastening of floor-mounted brackets (excluding heavy equipment that requires anchor rods), expansion anchors are permitted.

C. COLLARS:

1. Steel collars shall be tightly drawn to completely encircle covering, of length equal to twice the exterior diameter of the pipe covering; with longitudinal breaks 2" on center in lower 180o; painted before application; finish painted with pipe covering. Collars shall be as follows:

Size of Pipe Gauge of SM Collar

Up to 2" 28

2-1/2" to 4" 26

6" 24

2. At Contractor's option, steel collars may cover the lower 180o of pipe covering, providing they are securely strapped in place with 1" wide steel straps at each end, without damaging vapor barrier, canvas jacket, or covering.

Lower 180o steel collars may be replaced by collars made by Crawford, Elcen, Grinnell, or approved equal.

3. Steel collars must have flared edges to protect vapor barrier and must not puncture or destroy vapor barrier on pipe covering.

D. Acceptable Pipe Support Manufacturers:

1. Grinnell Company

2. B-Line Systems, Inc.

3. Unistrut

4. Substitutions: Under provisions of Section 01600.

E. Products used for pipe supports, hangers and accessories shall meet the requirements of MSS SP-58 and SP-69 where applicable unless shown otherwise shown or specified.

2.6 FABRICATION

A. Size sleeves large enough to allow for movement due to expansion and contraction. Provide for continuous insulation wrapping.

B. Design hangers for installation without disengagement of supported pipe.

2.7 FINISH

A. Prime coat all steel hangers and supports, unless galvanized, stainless steel or prefinished.

B. For prime coat refer to Section 09928 – Protective Coating Systems.

C. For finish coat refer to Section 09928 – Protective Coating Systems.


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PART 3 EXECUTION

3.1 GENERAL

A. Restrain, block, brace, support, or suspend pipe and fittings as shown on the Drawings and as required to prevent displacement, vibration, sagging, warping, deformation, or failure of piping and fittings while allowing for expansion and contraction.

B. Fabrication and installation of pipe hangers and supports shall be in accordance with MSS SP-89.

3.2 SUPPORT INSTALLATION

A. Locate hangers, supports, and accessories to support piping, valves, and at all concentrated loads.

B. Locate hangers, supports, and accessories within maximum span lengths specified to support continuous pipeline runs unaffected by concentrated loadings.

C. Install items to be embedded before concrete placement. Provide hooked rod to concrete reinforcement for inserts.

D. Fasten embedded items securely to prevent movement during concrete placement.

E. Install hangers and support units on piping systems as recommended by manufacturer.

F. Install all pipe saddles on 4 inch raised concrete pads complete with anchor bolts which extend through the support to the original floor. One inch grout pads may be substituted where approved by the Engineer.

G. Adjust hangers and supports and place grout for concrete supports to bring pipelines to specified elevations.

3.3 FLASHING INSTALLATION

A. Provide flexible flashing and metal counter flashing where piping and ductwork penetrate weather or waterproofed walls, floors, and roofs.

B. Flash vent and soil pipes in accordance with applicable specifications, projecting 3 inches minimum above finished roof surface.

For pipes through outside walls, turn flanges back into wall and caulk, metal counter flash and seal.

C. Seal floor, shower, mop sink and roof drains watertight to adjacent materials.

D. Provide curbs for mechanical roof installations with projection above roofing surface per details as developed on Drawings: Flexible sheet flash and counter flash with sheet metal; seal watertight.

3.4 INSTALLATION OF SLEEVES FOR PLUMBING AND MISCELLANEOUS PIPING

A. Set sleeves in position in formwork. Provide reinforcing around sleeves.

B. Extend sleeves through floors two (2) inches above finished floor level. Caulk sleeves full depth and provide floor plate.

C. Where piping or ductwork penetrates floor, ceiling, or wall, close off space between pipe or duct and adjacent Work with fire stopping insulation and seal air tight.

Provide close fitting metal collar or escutcheon covers at both sides of penetration.


WATER PLANTS


3.5 ACCEPTANCE AND SERVICE

A. Acceptance: All pipe systems shall be brought up to operating pressures and temperatures. Systems shall be cycled to duplicate operating conditions. All malfunctions shall be corrected.

B. Service: Contractor shall maintain and service all piping systems, hangers and supports for a period of one year after acceptance of the work. Contractor shall furnish all labor and materials to readjust and correct faults with hangers and supports for the piping systems installed.

END OF SECTION


WATER PLANTS

MECHANICAL IDENTIFICATION 15190-1

SECTION 15190

MECHANICAL IDENTIFICATION

PART 1 GENERAL


A. Identification of mechanical products installed under Division 15.


A. Section 09928 – Protective Coating Systems.

1.3 REFERENCES

A. ANSI/ASME A.13.1 - Scheme for the Identification of Piping Systems.

1.4 SUBMITTALS

A. Submit product data under provisions of Section 01330.

B. Submit list of wording, symbols, letter size, and color coding for mechanical identification.

C. Submit valve chart and schedule, including valve tag number, location, function, and valve manufacturer's name and model number.

D. Submit manufacturer's installation instructions under provisions of Section 01330.

PART 2 PRODUCTS


A. Seton

B. Brady

C. Substitutions: Under provisions of Section 01600.

2.2 MATERIALS

A. Plastic Nameplates: Laminated three-layer plastic with engraved black letters on light contrasting background color.

B. Plastic Tags: Laminated three-layer plastic with engraved black letters on light contrasting background color. Tag size minimum 1-1/2 inch diameter or square.

C. Metal Tags: Brass with stamped letters; tag size minimum 1-1/2 inch diameter with smooth edges.

D. Stencils: With clean cut symbols and letters of following size:

OUTSIDE DIAMETER OF LENGTH OF SIZE OF

INSULATION OR PIPE COLOR FIELD LETTERS

3/4" - 1-1/4" 8" 1/2"

1-1/2" - 2" 8" 3/4"

2-1/2" - 6" 12" 1-1/4"

8" - 10" 24" 2-1/2"

Over 10" 32" 3-1/2"

Ductwork and Equipment --- 2-1/2"


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MECHANICAL IDENTIFICATION 15190-2

E. Stencil Paint: In accordance with Section 09928, semi-gloss enamel.

F. Plastic Pipe Markers: Factory fabricated, flexible, semi- rigid plastic, preformed to fit around pipe or pipe covering; minimum information indicating flow direction arrow and fluid being conveyed.

G. Plastic Tape Pipe Markers: Flexible, vinyl film tape with pressure sensitive adhesive backing and printed markings.

H. Underground Plastic Pipe Markers: Bright colored continuously printed plastic ribbon tape of not less than 6 inch wide by 4 mil thick, manufactured for direct burial service.

PART 3 EXECUTION

3.1 PREPARATION

A. Degrease and clean surfaces to receive adhesive for identification materials.

B. Prepare surfaces in accordance with Section 09928 for painting.

3.2 INSTALLATION

Install identification system onto new work and existing mechanical installation.

A. Plastic Nameplates: Install with corrosive-resistant mechanical fasteners, or adhesive.

B. Metal Tags: Install with corrosive-resistant chain.

C. Stencil Painting: Apply in accordance with Section 09928.

D. Plastic Pipe Markers: Install in accordance with manufacturer's instructions.

E. Plastic Tape Pipe Markers: Install complete around pipe in accordance with manufacturer's instructions.

F. Underground Plastic Pipe Markers: Install 6 to 8 inches below finished grade, directly above buried pipe.

G. Equipment: Identify air handling units, pumps, heat transfer equipment, tanks, and water treatment devices with plastic nameplates. Small devices, such as in-line pumps, may be identified with plastic tags.

H. Controls: Identify control panels and major control components outside panels with plastic nameplates.

I. Valves: Identify valves in main and branch piping with tags.

J. Piping: Identify piping, concealed or exposed, with tags that may be used on small diameter piping. Identify service, flow direction, and pressure. Install in clear view and align with axis of piping. Locate identification not to exceed 20 feet on straight runs including risers and drops, adjacent to each valve and "T", at each side of penetration of structure or enclosure, and at each obstruction.

K. Ductwork: Identify ductwork with plastic nameplates. Identify as to air handling unit number, and area served. Locate identification at air handling unit, at each side of penetration of structure or enclosure, and at each obstruction.

3.3 VALVE CHART AND SCHEDULE AND IDENTIFICATION

Provide valve chart and schedule in aluminum frame with clear plastic shield. Install at location as directed.

END OF SECTION


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GAS PIPING AND APPURTENANCES

15192-1

SECTION 15192

NATURAL GAS PIPING AND APPURTENANCES


1.1 SUMMARY

Provide gas piping inside of buildings, including the supply line from the meter, service lines to gas equipment and appliances, termination of the service line with a ball valve, and final connection to equipment and appliances.


2.1 MANUFACTURERS

Stockham, Jenkins, Fisher, or Rockwell.

2.2 PIPE AND FITTINGS

A. Piping (Below Ground). Provide polyethylene resin conforming to ASTM D 1248, Type II, Grade 3, and with pipe properties conforming to ASTM D 2513. Provide piping with minimum wall thickness as required by SDR-11. Provide socket fittings through 2 inches, butt-fused fittings for 3 inches and larger. Provide Uponer, Tex-Tube or approved substitution.

B. Piping (Above Ground).

1. Pipe 2 Inches and Smaller. Provide Schedule 40, ASTM A 53, black steel with black 150-pound malleable iron threaded fittings. 2. Pipe Larger Than 2 Inches. Use Schedule 40, ASTM A 53, black steel pipe with long radius weld fittings.

C. Unions. Use 150-pound standard (300-pound water, oil or gas) malleable iron, ground joint unions, with bronze seat. Provide flange joints for pipe 3 inches and larger in diameter.

D. Flanges. Furnish Class 125 ANSI cast iron flanges.

2.3 VALVES

A. Ball Valves. For valves 2 inches and smaller, provide 600 psi CWP, cast brass 2-piece body, replaceable reinforced Teflon seats, full port, blowout-proof stem, chrome-plated brass ball, such as Stockham S-216-BR-RT, Nibco T-585-70-UL, or approved substitution.

B. Plug Valves. For valves 2-1/2 inches and larger, provide 150-pound, lubricated plus valves, ASTM A 126, Class B, with semi-steel body and tapered plug, such as Rockwell 142 (screwed) or Rockwell 143 (flanged). Provide flanged joints on valves 3 inches and larger.


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15192-2

2.4 GAS PRESSURE REGULATOR

Size the gas pressure regulator in accordance with the manufacturer’s recommendations for flow quantities and reduced pressure, as shown on drawings. Provide Fisher Series S100 (less than 1000 cfh) or Series 200 (greater than 1000 cfh) regulators or approved substitution, suitable for outdoor installation.


3.1 PREPARATION

The serving utility will provide connection to an existing gas main and service to the meter. Give proper notice and pay all fees and other costs for complete gas service.

3.2 INSTALLATION

A. Installation Standards. Install gas piping in accordance with recommendations of the National Fire Protection Association.

B. Drip Legs. Install a capped drip leg 6 inches long at the base of each vertical riser.

C. Coating and Wrapping. Coat and wrap underground piping in accordance with the standards of the servicing utility.

D. Sleeves.

1. Encase all gas piping running in or through solid partitions, above ceilings in space used as a return air plenum or which is unventilated and in all other areas or spaces within the building in which gas might collect or from which gas might be introduced into supply or return air systems. For encasement or sleeving, use Schedule 10, black steel pipe and fittings conforming to ASTM A 120, with welded joints. Sleeve piping and fittings must be two pipe sizes, but not less than 1 inch larger than encased gas piping. Vent sleeve to outside, or to nearest ventilated space discharging to outside. 2. Encase gas piping running below slab in a service-weight cast iron conduit, minimum size two pipe sizes larger than gas pipe. Vent conduit to ventilated space inside building and with a 3/4-inch vent with 3/4-inch return bend 4 inches above finish grade outside of building.

3.3 TESTING GAS PIPING

A. Apply 50 psig air pressure.

B. Test all joints with a soap solution while lines are under pressure.

C. Repair all leaks.

D. Make a final 24-hour standing pressure test with air at 20 psi before connecting equipment.

3.3 TESTING HIGH PRESSURE GAS PIPING

A. Apply 100 psi air pressure.

B. Test all joints with a soap solution while lines are under pressure.


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15192-3

C. Repair all leaks.

D. Apply an air pressure 1-1/2 times the normal operating pressure, 150 psig minimum, to the system and test all joints with a soap solution while lines are under pressure.

E. Repair all leaks.

F. Retest the system until it is proven free of leaks.

END OF SECTION


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15192-4

BLANK PAGE


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PLUMBING 15410-1

SECTION 15410

PLUMBING

PART 1 - GENERAL


A. Scope: All plumbing and natural gas piping systems as shown, specified and required.

B. The work includes, but is not limited to, the following:

1. Pipe and pipe fittings.

2. Valves.

3. Sanitary sewer piping system.

4. Domestic water piping system.

5. Compressed air piping system.

6. Stormwater Piping System.


A. Section 02223 – Earthwork.

B. Section 02315 – Excavation, Trenching and Backfilling for Utilities.

C. Section 09928 – Protective Coating Systems.

D. Section 15105 – Pipe and Pipe Fittings.

E. Section 15106 – Ductile Iron Pipe and Fittings.

F. Section 15030 – Erecting and Jointing Interior Plant Process Piping

G. Section 15140 – Supports and Anchors..

1.3 REFERENCES

A. ANSI/ASME B16.3 - Malleable Iron Threaded Fittings Class 150 NS 300.

B. ANSI/ASME B16.23 - Cast Copper Alloy Solder Joint Drainage Fittings - DWV.

C. ANSI/ASME B16.29 - Wrought Copper and Wrought Copper Alloy Solder Joint Drainage Fittings - DWV.

D. ANSI/ASME Sec. 9 - Welding and Brazing Qualifications.

E. ANSI/ASTM B32 - Solder Metal.

F. ANSI/ASTM C443 - Joints for Circular Concrete Sewer and Culvert Pipe, Using Rubber Gaskets.

G. ANSI/ASTM C700 - Vitrified Clay Pipe, Extra Strength, Standard Strength, and Perforated.

H. ANSI/ASTM D2466 - Poly Vinyl Chloride Plastic Pipe Fittings, Schedule 40.

I. ANSI/AWS D1.1 - Structural Welding Code.

J. ANSI/AWWA C105 - Polyethylene Encasement for Ductile Iron Piping for Water and Other Liquids.

K. ANSI/AWWA C110 - Ductile-Iron and Gray-Iron Fittings 3" thru 48" for Water and Other Liquids.


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PLUMBING 15410-2

L. ANSI/AWWA C111- Rubber-Gasket Joints for Ductile Iron and Gray-Iron Pressure Pipe & Fittings.

M. ANSI/AWWA C151 - Ductile-Iron Pipe, Centrifugally Cast in Metal or Sand-Lined Molds, for Water or Other Liquids

N. ASME - Boiler and Pressure Vessel Code.

O. ASTM A53 - Pipe, Steel, Black and Hot-Dipped Zinc Coated, Welded and Seamless (for coiling, blending, flanging & other special purposes).

P. ASTM A74 - Cast Iron Soil Pipe and Fittings.

Q. ASTM A120 - Pipe, Steel, Black and Hot-Dipped Zinc Coated (Galvanized), Welded and Seamless (for Ordinary Uses).

R. ASTM A234 - Pipe Fittings of Wrought Carbon Steel and Alloy Steel for Moderate & Elevated Temperatures

S. ASTM B88 - Seamless Copper Water Tube.

T. ASTM B306 - Copper Drainage Tube (DWV).

U. ASTM C14 - Concrete Sewer, Storm Drain, and Culvert Pipe.

V. ASTM C425 - Compression Joints for Vitrified Clay Pipe and Fittings.

W. ASTM C564 - Rubber Gaskets for Cast Iron Soil Pipe and Fittings.

X. ASTM D1785 - Poly Vinyl Chloride Plastic Pipe, Schedules 40, 80, and 120.

Y. ASTM D2235 - Solvent Cement for Acrylonitrile-Butadiene -Styrene (ABS) Plastic Pipe & Fittings

Z. ASTM D2855 - Making Solvent - Cemented Joints with Poly Vinyl Chloride Pipe and Fittings.

AA. AWWA 16th Edition - Standard Methods for the Examination of Water and Waste Water.


A. Valves: Manufacturer's name and pressure rating marked on valve body.

B. Welding Materials and Procedures: Conform to ASME Code and applicable state labor regulations.

C. Welders Certification: In accordance with ANSI/ASME Section 9.

1.5 SUBMITTALS

A. Submit product data under provisions of Section 01330 and Section 15010.

B. Include data on pipe materials, pipe fittings, valves and accessories.


A. Deliver products to site under provisions of Section 01600.

B. Store and protect products under provisions of Section 01600.

C. Deliver and store valves in shipping containers with labeling in place.


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PLUMBING 15410-3

PART 2 - PRODUCTS

2.1 SANITARY SEWER PIPING AND FLOOR DRAIN PIPE, BURIED WITHIN 5 FEET OF BUILDING

A. Cast Iron Soil Pipe: ASTM A74, black coated, extra heavy weight.

B. Fittings: Cast iron.

C. Joints: Hub-and-spigot, compression type with ASTM C564 neoprene gaskets or lead and oakum.

2.2 DOMESTIC WATER PIPING, BURIED BEYOND 5 FEET OF BUILDING

As specified under applicable pipe material specifications.

2.3 DOMESTIC WATER PIPING, BURIED WITHIN 5 FEET OF BUILDING

A. Ductile Iron Pipe: ANSI/AWWA C151.

Fittings: iron, standard thickness.

Joints: ANSI/AWWA C111, rubber gasket restrained against movement.

2.4 DOMESTIC WATER PIPING, ABOVE GRADE

A. Copper Tubing: ASTM B88, Type K, hard drawn.

B. Fittings: ANSI/ASME B16.23, cast brass, or ANSI/ASME B16.29, wrought copper.

C. Joints: ANSI/ASTM B32, solder, Grade Sb5 (95-5TA).

D. Use for all water piping except where noted.

2.5 STORM WATER PIPING, BURIED BEYOND 5 FEET OF BUILDING

As specified under applicable pipe material specifications.

2.6 STORM WATER PIPING, BURIED WITHIN 5 FEET OF BUILDING.

A. Cast Iron Soil Pipe: ASTM A74, black coated, extra heavy weight.

B. Fittings: Cast iron.


D. Use for all storm water piping except where noted.

2.7 STORM WATER PIPING, ABOVE GRADE (INSIDE OF BUILDING)

A. Cast Iron Soil Pipe: ASTM A74, black coated, service weight.

B. Fittings: Cast Iron.


D. Use for all storm water piping except where noted.

2.8 COMPRESSED AIR PIPING ABOVE GRADE (INSIDE OF BUILDING)

A. Steel Pipe: ASTM A53 or A120, Schedule 40, Galvanized, Grade B. Type E.

B. Fittings: ANSI/ASME B16.3, malleable iron, or ASTM A234, forged steel welding type, galvanized.

C. Joints: Pipe 2" and smaller: Screwed Pipe larger than 2": ANSI/AWS D1.1, welded

2.9 SUMP PUMP DISCHARGE & SUCTION

A. Steel Pipe (Less than 3"): ASTM A-120, Galvanized steel schedule 40.


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PLUMBING 15410-4

B. Fittings: Screwed fittings, taper-topped coupling type with thread in accordance with ANSI B2.1, and galvanized.

C. Joints: Screwed.

2.10 UNIONS

A. Unions shall be installed adjacent to threaded devices and in all locations required to permit easy removal of devices and piping.

B. The use of running threads or right and left hand couplings instead of unions will not be permitted.

2.11 FLANGES, COUPLINGS AND DIELECTRIC CONNECTIONS

A. Pipe Size 2 Inches and Under: 150 psig malleable iron unions for threaded ferrous piping; bronze unions for copper pipe, soldered joints.

B. Pipe Size Over 2 Inches: 150 psig forged steel slip-on flanges for ferrous piping; bronze flanges for copper piping; neoprene gaskets for gas service; 1/16 inch thick preformed rubber sheet packing.

C. Grooved and Shouldered Pipe End Couplings: Malleable iron housing clamps to engage and lock, designed to permit some angular deflection, contraction, and expansion; "C" shape composition sealing gasket; steel bolts, nuts, and washers; galvanized couplings for galvanized pipe.

D. Dielectric Connections: Union with galvanized or plated steel threaded end, copper solder end, water impervious isolation barrier.

2.12 ACCEPTABLE MANUFACTURERS - BALL VALVES

A. Less than 2": Nibco Model T585-70

B. Substitutions: Under provisions of Section 01600.

2.13 BALL VALVES

A. Up to 2 Inches: 2 piece design with a brass body, stainless steel ball, reinforced TFE seats and stuffing box ring, lever handle threaded ends, 600 psi CWP, Full Pont.

2.14 ACCEPTABLE MANUFACTURERS - DIELECTRIC FITTING

A. Central Plastics Co.

B. Epco Sales

C. Substitutions: Under provisions of Section 01600.

2.15 DIELECTRIC FITTING

A. In all cases where dissimilar metals such as connecting copper or brass to iron or steel arises, corrosion caused by galvanic action shall be avoided by insulating the connection by means of a dielectric flange.

B. The strength of the coupling or connection shall in no case be less than the pipe to which it is connected.


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PLUMBING 15410-5

PART 3 - EXECUTION

3.1 PREPARATION

A. Ream pipe and tube ends. Remove burrs.

B. Remove scale and dirt, on inside and outside, before assembly.

C. Prepare piping connections to equipment with flanges or unions.

3.2 INSTALLATION

A. Provide non-conducting dielectric connections wherever jointing dissimilar metals.

B. Route piping in orderly manner and maintain gradient.

C. Install piping to conserve building space and not interfere with use of space.

D. Group piping whenever practical at common elevations.

E. Install piping to allow for expansion and contraction without stressing pipe, joints, or connected equipment.

F. Provide clearance for access to valves and fittings.

G. Slope water piping and arrange to drain at low points.

H. Establish elevations of buried piping outside the building to ensure not less than five (5) ft. of cover.

I. Where pipe support members are welded to structural building framing, scrape, brush clean, and apply one coat of zinc rich primer to welding.

J. Prepare pipe, fittings, supports, and accessories not prefinished, ready for finish painting. Refer to Section 09928.

K. Establish invert elevations, slopes for drainage to be minimum of 1/4 inch per foot except as noted. Maintain gradients.

L. Excavate in accordance with Section 02223.

M. Backfill in accordance with Section 02315.

N. Install bell and spigot pipe with bell end upstream.

O. Install valves with stems upright or horizontal, not inverted.

P. Refer to Section 15030 - Erecting and Jointing Interior Plant Process Piping for specific requirements.

3.3 APPLICATION

A. Use grooved mechanical couplings and fasteners only in accessible locations.

B. Install unions downstream of valves and at equipment or apparatus connections.

C. Install brass male adapters each side of valves in copper piped system. Sweat solder adapters to pipe.

D. Install ball valves for shut-off and to isolate equipment, part of systems, or vertical risers.

E. Install globe valves for throttling, bypass, or manual flow control services.

F. Provide check valves on discharge of water pumps.

3.4 DISINFECTION OF DOMESTIC WATER PIPING SYSTEM

A. Prior to starting Work, verify system is complete, flushed and clean.


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PLUMBING 15410-6

B. Inject disinfectant, free chlorine in liquid, powder, tablet or gas form, throughout system to obtain 50 to 80 mg/L residual.

C. Bleed water from outlets to ensure distribution and test for disinfectant residual at minimum 15 percent of outlets.

D. Maintain disinfectant in system for 24 hours.

E. If final disinfectant residual tests less than 25 mg/L, repeat treatment.

F. Flush disinfectant from system until residual equal to that of incoming water or 1.0 mg/L.

G. Take samples no sooner than 24 hours after flushing, from 10 percent of outlets and from water entry, and analyze in accordance with AWWA C651.

END OF SECTION


WATER PLANTS

FANS 15830-1

SECTION 15830

FANS

PART 1 GENERAL

1.1 SUMMARY

Provide fans, propeller types, with all supplemental equipment.

1.2 PERFORMANCE

A. Provide fan type, arrangement, rotation, capacity, size, motor horsepower, and motor voltage as shown. Fan capacities and characteristics are scheduled on the drawings.

B. Rate fans according to appropriate Air Moving and Conditioning Association, Inc. (AMCA), approved test codes and procedures. Supply fans with sound ratings below the maximums permitted by AMCA standards. All fans provided must be licensed to bear the Certified Ratings Seal.

C. Statically and dynamically balance all fans.

PART 2 PRODUCTS

2.1 ACCEPTABLE MANUFACTURER’S:(to comply with the drawing requirements)

A. Greenheck

B. Hartzell

C. Cook

2.2 PROTECTIVE COATINGS

A. Vinyl Plastic. Coat surfaces, where required, with vinyl plastic, air-dried Heresite, or an approved substitution. Have the product factory applied to fan wheels and interior surfaces of casings. Apply a minimum of three coats.

2.3 SUPPLEMENTAL EQUIPMENT

A. Safety Disconnect Switch. Provide a factory-wired, safety disconnect switch on each unit equipped with a 115/1/60 motor.

B. Bird Screen. Provide 1/2-inch mesh, galvanized bird screens. Include dampers where shown.

2.4 WALL-MOUNTED SUPPLY OR EXHAUST FAN (DIRECT DRIVEN)

Furnish direct-driven, propeller-type fans designed for mounting in the wall. Mount the fan wheel and motor on a square, flanged panel made of steel and formed with a venturi orifice. Provide coorosion resistant protective coating. Provide fans with a drive-side, galvanized wire guard.


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FANS 15830-2

PART 3 EXECUTION

3.1 INSTALLATION

Install fans according to the manufacturer’s written instructions and in the locations shown on the drawings. Coordinate location of fans with architectural drawings.

END OF SECTION


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ELECTRICAL GENERAL PROVISIONS

16050-1

SECTION 16050




This section includes the requirements for the provision of all labor, materials and equipment required for complete and functioning electrical systems as required by the contract documents.

A. New Work. The work includes, but is not limited to, the following principal systems and equipment:

1. 480 volt distribution. 2. 208/120 volt distribution. 3. Raceway systems for communication system cables. 4. Low voltage motor control. 5. Panelboards. 6. Transformers. 7. Lighting fixtures, poles, lamps and ballasts.

1.2 APPLICABLE PROVISIONS

A. Provisions Specified Elsewhere. Unless modified in this section, General and Supplementary General Conditions, applicable provisions of Division 1 - General and other provisions of contract documents apply to work of Division 16 - Electrical.

B. Application. Provisions of this section apply to every section of Division 16 - Electrical, except where specifically modified.

1.3 REFERENCE CODES AND STANDARDS

Standards of the following organizations may be referenced in the specification. Unless noted otherwise, references are to standards or codes current at the time of bidding.

A. Association of Edison Illuminating Companies (AEIC).

B. American National Standards Institute (ANSI).

C. Institute of Electrical and Electronics Engineers (IEEE).

D. Insulated Cable Engineers Association (ICEA).

E. National Electrical Code (NEC).

F. National Electrical Contractors Association (NECA).

G. National Electrical Manufacturers Association (NEMA).

H. National Electrical Safety Code (NESC).


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16050-2

I. National Electrical Testing Association (NETA).

J. National Fire Protection Association (NFPA).

K. Underwriters' Laboratories (UL).

1.4 REGULATIONS AND PERMITS

A. Regulations. Work, materials and equipment must comply with the latest rules and regulations of the following:

1. National Electrical Code (NEC). 2. National Electrical Safety Code (NESC). 3. Occupational Safety and Health Act (OSHA). 4. Americans with Disabilities Act (ADA). 5. Local, state and federal codes, ordinances and regulations.

B. Discrepancies. The drawings and specifications are intended to comply with listed codes, ordinances, regulations and standards. Where discrepancies occur, immediately notify the Owner's representative in writing and ask for an interpretation. Should installed materials or workmanship fail to comply, the Contractor is responsible for correcting the improper installation. Additionally, where sizes, capacities, or other such features are required in excess of minimum code or standards requirements, provide those specified or shown.

C. Permits. Obtain certificates of inspection and other permits required as a part of the work.

1.5 CONTRACT DRAWINGS

A. Intent. The intent of the drawings is to establish the types of systems and functions, but not to set forth each item essential to the functioning of the system. Electrical drawings are generally diagrammatic and show approximate location and extent of work. Install the work complete, including minor details necessary to perform the function indicated. In case of doubt as to work intended, or if amplification or clarification is needed, request instructions from the Owner's representative.

B. Discrepancies. Review pertinent drawings and adjust the work to conditions shown. Where discrepancies occur between drawings, specifications, and actual field conditions, immediately notify the Owner's representative for his interpretation.

C. Outlet and Equipment Locations. Coordinate the actual locations of electrical outlets and equipment with building features and equipment as indicated on architectural, structural, mechanical and plumbing drawings. Review with the Owner's representative any proposed changes in outlet or equipment location. Relocation of outlets before installation, of up to 5 feet from the position indicated, may be directed without additional cost. Remove and relocate outlets placed in an unsuitable location, when so requested by the Owner's representative.

1.6 CONTRACTOR QUALIFICATIONS

An acceptable Contractor for the work under this division must have personnel with experience, training and skill to provide a practical working system. The Contractor may be required to furnish acceptable evidence of having installed not less than three systems of size and type comparable to this project. The systems must have served satisfactorily for not less than 3 years. The superintendent must have had experience in installing not less than three such systems.


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16050-3


2.1 PRODUCT REQUIREMENTS

A. Condition. Provide new products of manufacturers regularly engaged in production of such equipment. Provide the manufacturer's latest standard design for the type of product specified.

B. NEC and UL. Products must conform to requirements of the National Electrical Code. Where Underwriters' Laboratories have set standards, listed products and issued labels, products used must be listed and labeled by UL.

C. Space Limitations. Equipment selected must conform to the building features and must be coordinated with them. Do not provide equipment which will not suit arrangement and space limitations.

D. Factory Finish. Equipment must be delivered with a hard surface, factory-applied finish so that no additional field painting is required except for touch-up as required.

2.2 SUBSTITUTIONS

Refer to Section 01600, Product Requirements.


3.1 PROTECTION OF EQUIPMENT

A. Moisture. During construction, protect switchgear, transformers, motors, control equipment, and other items from insulation moisture absorption and metallic component corrosion by appropriate use of strip heaters, lamps or other suitable means. Apply protection immediately on receiving the products and maintain continually.

B. Clean. Keep products clean by elevating above ground or floor and by using suitable coverings.

C. Damage. Take such precautions as are necessary to protect apparatus and materials from damage. Failure to protect materials is sufficient cause for rejection of the apparatus or material in question.

D. Finish. Protect factory finish from damage during construction operations and until acceptance of the project. Satisfactorily restore any finishes that become stained or damaged.

3.2 INSTALLATION

A. Cooperation with Other Trades. Cooperation with trades of adjacent, related or affected materials or operations, and of trades performing continuations of this work under subsequent contracts, is considered a part of this work in order to effect timely and accurate placing of work and to bring together, in proper and correct sequence, the work of such trades.

B. Workmanship. Work must be performed by workmen skilled in their trade. The installation must be complete. Provide work in accordance with NECA 1.

C. Concrete Equipment Pads. Install 3-1/2-inch-thick concrete foundation pads for indoor floor-mounted equipment, except where direct floor mounting is required. Pour pads on roughened floor slabs,


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16050-4

sized so that outer edges extend a minimum of 3 inches beyond equipment. Trowel pads smooth and chamfer edges to a 1-inch bevel. Secure equipment to pads as recommended by the manufacturer.

D. Setting of Equipment. Equipment must be leveled and set plumb. Sheet metal enclosures mounted against a wall must be separated from the wall not less than 1/4 inch by means of corrosion-resistant spacers or by 3 inches of air for freestanding units. Use corrosion-resistant bolts, nuts and washers to anchor equipment. In sufficient time to be coordinated with work under other divisions, provide drawings and layout work showing exact size and location of sleeves, openings or inserts for electrical equipment in slabs, walls, partitions and chases.

E. Sealing of Equipment.

1. Voids between sleeves or core-drilled holes and pipe passing through fire-rated assemblies shall be firestopped to meet the requirements of ASTM E 814, in accordance with Section 07840, Firestopping. Contractors shall provide proper sizing when providing sleeves or core-drilled holes to accommodate their through-penetrating items. 2. Seal openings into equipment to prevent entrance of animals, birds and insects.

F. Motors.

1. Motors are specified under other sections of Division 16. 2. Electrical work includes the electrical connection of all motors, except those which are wired as a part of equipment.

G. Concealed Work. Conceal all electrical work in walls, floors, chases, under floors, underground and above ceilings except:

1. Where shown or specified to be exposed. Exposed is understood to mean open to view. 2. Where exposure is necessary to the proper function. 3. Where size of materials and equipment preclude concealment.

H. Application. Unless otherwise indicated, power will be utilized as follows:

1. 480 volts, three phase: motors above 3/4. 2. 120 volts, single phase: motors 1/2 horsepower and smaller. 3. 120 volts, single phase: incandescent lighting. 4. 120 volts, single phase: fluorescent lighting. 5. 120, 208 or 480 volts, single phase: high-intensity-discharge lighting. 6. 120 volts, single phase: convenience outlets.

I. Transformers. Use transformers to change the service to the required utilization voltages.

J. Load Balancing. All loads must be balanced with no phase load being more than 10% of another.

3.3 TESTING

A. Test Conditions. Place circuits and equipment into service under normal conditions, collectively and separately, as may be necessary to determine satisfactory operation. Perform specified tests in the presence of the Owner's representative. Furnish all instruments, wiring, equipment and personnel required for conducting tests. Demonstrate that the equipment operates in accordance with requirements of the drawings and specifications. Special tests on certain items are specified hereinafter. Where specified that the testing be performed by an independent testing company, an Owner approved NETA certified testing company shall be used.


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16050-5

B. Test Dates. Schedule final acceptance tests sufficiently in advance of the contract date to permit completion of any necessary adjustment or alterations within the number of days allotted for completion of the contract.

C. Retests. Conduct retests as directed by the Owner's representative of such time duration as may be necessary to assure proper functioning of adjusted or altered parts or items of equipment. Any resultant delay as a result of such necessary retests does not relieve the Contractor of his responsibility under this contract.

END OF SECTION


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16050-6



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ACCEPTANCE TESTING AND CALIBRATION 16051-1

SECTION 16051

ACCEPTANCE TESTING AND CALIBRATION



This section provides the guidelines for testing of electrical equipment, low voltage cable, protective relays, circuit breakers, motor control centers, motors, and related apparatus to be used for the site interior and exterior electrical distribution system. This specification does not release the CONTRACTOR or vendor from any further testing required for safe commissioning of the equipment.


National Electric Testing Association Standards for acceptance testing of Electrical Distribution Apparatus, Publication 2.001, and IEEE Publication No. 141, are hereby made a part of this section, unless otherwise modified herein.

1.3 TESTS

A. All tests, other than Low Voltage Systems and Equipment, will be supervised by the OWNER. THE CONTRACTOR will give a one-week notice of all scheduled tests to the OWNER in writing. If a third party is conducting the tests, the CONTRACTOR's presence will be required also.

B. Provide tests as required by specific sections of these Division 16 specifications. Review Division 16 requirements for other testing not specifically mention in this section.

C. Under this specification the CONTRACTOR shall perform the electrical tests on the following equipment and as specified under Part 3, Execution. The CONTRACTOR will supply all equipment required to perform all testing responsibilities.

1. All transformers. 2. Low voltage cable. 3. Motors. 4. All controls for miscellaneous motors. 5. Motor control centers. 6. Grounding.

D. The Contractor will notify the Owner of scheduled dates of electrical equipment installation completion. Equipment testing will be coordinated at this time by Contractor with Owner and appropriate Manufacturer's Representatives.


Not used.


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3.1 PREPARATORY WORK

Prior to the testing of any specific piece of equipment, the Contractor will remove all shipping hardware and inspect for broken or missing parts and proper connections in accordance with the manufacturer's instructions.

3.2 MOTOR STARTERS

A. Test, adjust, and clean motor starters as required by design specifications and manufacturer's published instructions.

B. Record all nameplate data on starters and motors and information on components such as fuses, current transformer ratios, overload relays, and settings. Test ground fault relays.

C. Check all connections for tightness. Check all contacts for proper alignment and pressure. Verify that all movable parts are free to operate.

D. Take insulation resistance readings of components using 1,000-volt megger for equipment rated 440 to 600 volts. Investigate and correct the causes if an insulation resistance less than one megohm is noted.

E. Check the starter control sequence by using a source of control voltage, and dropping it through each of its protective devices, interlocks, pushbuttons, etc.

F. Check all fuses for continuity and proper rating.

G. Verify that all secondary circuits of current transformers are connected.

H. Check all space heaters and related circuitry.

3.3 MOTOR CONTROL CENTERS

A. Visually inspect the centers externally and internally (bus-bracing, loosened frame bolts, etc.) for damage or possible trouble before making any tests. Wipe clean the center of all construction dirt and dust.

B. With all the starters open, including the main, megger the bus, phase-to-phase and phase-to-ground using a 500V megger.

C. Confirm starter heater size with actual full load current of corresponding motors.

D. Before motors are run for plant start-up, megger motor cables with a 500V megger with the motor connected. Jog the motor to determine correct rotation and after rotating is confirmed correct, set the motor circuit protector breakers per manufacturers recommended procedure.

E. With motor overloads removed, confirm proper operation of a motor control circuit, including all start and stop permissive, interlocks, and trip functions.

3.4 GENERAL

Submit directly to the ENGINEER six (6) copies of all test reports certified by the testing technician.


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END OF SECTION


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11000-B – MANUFACTURER'S INSTRUCTION CERTIFICATION FORM

Contract No.: ________________________ Specification Section: _________________

Equipment Name: _____________________________________________________________

Contractor: ___________________________________________________________________

Manufacturers of an equipment item: ______________________________________________

The undersigned manufacturer certifies that a service ENGINEER has instructed the wastewater treatment operating personnel in the proper maintenance and operation of the equipment designated herein.

Operations Check List (check appropriate spaces)

Start-up procedure reviewed

Shutdown procedure reviewed

Normal operation procedure reviewed

Others:

Maintenance Check List (check appropriate spaces)

Described normal oil changes (frequency)

Described special tools required

Described normal items to be reviewed for wear

Described preventive maintenance instructions

Described greasing frequency

Others:

Date: _________________ Manufacturer: __________________________________

Signature of Authorized Representative

Date: _________________ _________________________________

Signature of Owner's Representative

Date: ______________ __________________________________


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Signature of Contractor's Representative


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11000-A – MANUFACTURER'S INSTALLATION CERTIFICATION FORM

Contract No.:___________________ Specification Section: __________________ Equipment Name: ______________________________________________________________ Contractor: ___________________________________________________________________ Manufacturer of equipment item: __________________________________________________

The undersigned manufacturer of the equipment item described above hereby certifies that he has checked the installation of the equipment and that the equipment, as specified in the project manual, has been provided in accordance with the manufacturer's recommendations and that the trial operation of the equipment item has been satisfactory.

Comments: __________________________________________________________________

Date: ______________ Manufacturer: ___________________________________________

Signature of Authorized Representative: ____________________________________________

Date: ______________ Contractor: _____________________________________________

Signature of Authorized Representative: ____________________________________________


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TRANSFORMER TEST REPORT

PROJECT NO.: ______________________

OWNER: ____________________________________________________________________

CONTRACTOR: ______________________________________________________________

ENGINEER: __________________________________________________________________

PROJECT: ____________________________________________________________________

REFERENCE DATA:

Report No. ____________ Description: _________________________________________

Specification Section No. Page No. Paragraph No. ________

Sheet No. Entitled

_________________________________________________________________

Detail Designation Drawing Attached (Y/N) _______

EQUIPMENT IDENTIFICATION:

Name (From Drawings) _______________________________________________________

Identification No. Unit No. _______________________

Manufacturer ________________________________________________________________

Model No. Serial No._________________________

LOCATION: Structure ___________________________________________________________________

N/S Coord. E/W Coord. Station Elev. _______________

RESISTANCE TESTER

Mfgr. Model No. Serial No. ____________________________

Range Megohms MaxVoltage vdc

WEATHER oF % RH DATE ____________________

KVA PHASE ___________________________

PRIMARY VOLTAGE SECONDARY VOLTAGE ______________

Primary Insulation Resistance

(Megahoms after 15 sec.)

Secondary Insulation Resistance

(Megahoms after 15 sec.)

Phase A Phase B Phase C Phase A Phase B Phase C


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Test by: ________________________________

Witness by: _____________________________

Test by: ________________________________

Witness by: ______________________________


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IDENTIFICATIONS 16052-1

SECTION 16052

IDENTIFICATIONS



This section includes the requirements for the provision and installation of tags/nameplates on all equipment, devices, instruments, conduit, and conductor marked as indicated on the drawings and as specified herein. Major equipment shall be furnished with nameplates in accordance with their individual specifications.


2.1 EQUIPMENT AND DEVICE MARKING

A. Designations. Identify all equipment, devices, feeders, branch circuits and similar items with the same designations as indicated on the contract documents.

B. Nameplates. Externally mark all electrical equipment with nameplates identifying each and the equipment served. Nameplates shall be black laminated rigid phenolic with white core. Nameplate minimum size shall be 1 inch high by 3 inches long with 3/16-inch-high engraved white letters. Supply blank nameplates for spare units and spaces.

C. Nameplate Fasteners. Fasten nameplates to the front of equipment only by means of stainless steel self-taping screws. Stick-ons or adhesives will not be allowed unless the NEMA enclosure rating is compromised, then only epoxy adhesive shall be used to attach nameplates.

D. Nameplate Information. In general, the following information is to be provided for the types of electrical equipment as listed.

1. Switchgear. On main switches or circuit breakers, identify the system voltage. For each switch or circuit, identify the load served. 2. Motor Control Centers. On the mains identify the piece of equipment, the source and voltage characteristics (i.e., 480V 3PH 3W). For each branch circuit protective device, identify the load served. 3. Transformers, Individual Starters, Contactors, Disconnect Switches, Transfer Switches and similar equipment. Identify the device designation, source and load served. 4. Panelboards. Identify the source, panelboard designation and voltage characteristics.

E. Panelboards. Prepare a neatly typed circuit directory behind clear heat-resistant plastic in a metal frame attached to the inside of the door for each panelboard. Identify circuits by equipment served and by room numbers where room numbers exist. Indicate spares and spaces with light, erasable pencil marking. Adhesive mounted directory pocket is not acceptable.

F. Pull, Junction and Outlet Boxes. With 1/2-inch-high lettering, identify conduits connected to pull, junction and outlet boxes with the complete circuit number of the conductors contained therein. Where multiple circuits are contained in a box, identify the circuit conductors with permanent tags which indicate circuit designation.


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G. Power Receptacles. Use nameplate or engrave device plate to identify power receptacles where the nominal voltage between any pair of contacts is greater than 150 volts with circuit number, voltage and phases. If nameplates are used, attach to wall directly above device plate.

I. Wall Switches. Where the equipment served is not in sight of the wall switch, provide an engraved switch plate or attach a nameplate to the wall directly above the switch.

2.2 CONDUCTORS IDENTIFICATION SYSTEM

A. Provide heat-shrink wire markers, or approved equal, for conductor identification.

B. Provide complete power and control conductor identification system so that after installation circuits can be easily traced from origin to final destination.

C. Identify power and control conductors at each termination and in all accessible locations such as manholes, handholes, panels, switchboards, pull boxes, terminal boxes, etc. For identification, use type of tags specified herein.

D. Tag conductors using a three-segment conductor numbering scheme which defines the origin of the conductor, the function of the conductor, and the destination of the conductor.

E. Example: MCC-B1-A1-AIR where MCC-B1, Cubicle A1 is the origin.

F. Make the origin and destination identification the specific names for the equipment used in the Contract Documents.

2.3 CONDUIT MARKERS

Conduit markers shall be the metal type permitting embossing on the job.

2.4 POWER OUTLETS, SWITCHES, AND PILOT DEVICES

A. Mark power outlets with voltage, phase, and circuit number.

B. Identify all wall switches, disconnect switches, etc., with name tags and circuits served.

C. Identify all pushbutton stations with their functions and equipment served.

2.5 EXPOSED CONDUITS AND CABLES ON CABLE TRAY

Identify all exposed conduits and cables by their circuit numbers or loop numbers at the source, at the equipment, and at 20 feet spans in between.


3.1 CONDUIT MARKERS

A. Exposed Conduits.

1. Furnish conduit markers at the point of origin, point of termination upon crossing on each side, and at 50-foot intervals for all exposed and accessible conduits.


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2. Install markers lengthwise and attach with cable ties. 3. Stencil high voltage conduit with the legend "high voltage" stenciled in minimum 1-inch high red letters.

B. Underground Conduit Duct Banks.

1. Mark underground ductbanks with 24-inch by 24-inch by 4-inch concrete marker with etched lettering and arrows indicating the ductbank route. 2. Install markers at point of origin, at point of termination, at change of direction, and at 100-foot intervals, even though not shown on plans.

3.2 CONDUCTORS

Tag all conductors at their origin, termination, pullboxes and junction boxes.

3.3 NAMEPLATES/TAGS

A. Furnish and install nameplates for all switchgear, panelboards, motor starters, motor control centers, disconnect switches, instrument panels, dry-type transformers, and control stations.

B. Engrave the equipment designation, on nameplates. All switches, indicating lights, pushbuttons, meters, and parameter indicators on panels shall be clearly identified with its function or tag, as required.

C. Stainless steel tags shall be used on instrument, motors, and other devices, as applicable. The tags shall be affixed to the instrument with drive pins or stainless steel wire in such manner that it does not need to be removed to install the instrument. Motors shall carry the tag assigned to its driven equipment, i.e., P-101.

END OF SECTION


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GROUNDING 16060-1

SECTION 16060

GROUNDING



This section specifies the furnishing and installation of grounding and bonding equipment for electrical systems.


Design, test, assemble and install in conformance to the latest edition of the following applicable industry standards.

A. ANSI/IEEE Std 142 - Recommended Practice for Grounding of Industrial and Commercial Power Systems.

B. ANSI/UL 467 - Grounding and Bonding Equipment.

1.3 SUBMITTALS

Submit product data.


2.1 GROUND RODS

A. Materials. Provide 3/4-inch by 10-foot long, copper-clad, steel grounding electrodes. Supply a rod to which the copper cladding is permanently and inseparably bonded to a high-strength steel core.

B. Listing. UL 467.

2.2 CONNECTIONS

A. Materials. Provide exothermic welded type connections for all grounding and bonding connections. Obtain written permission from the Engineer for the use of non-exothermic connections.

B. Listing. UL 467.

2.3 WIRING

A. Grounding Electrode Conductors. Bare tinned-copper conductors, minimum size of #4/0 AWG, stranded.

B. Equipment Grounding Conductors. Provide bare tinned-copper conductors for bonding jumpers. Provide 600-volt insulated stranded copper conductors having a green-colored insulation for equipment grounding conductors.


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GROUNDING 16060-2

C. Listing. UL 83.

2.4 GROUND BUS

Where a field-provided ground bus is required, use round-edge copper bar with 98 percent International Annealed Copper Standard (IACS) conductivity. Size the bus for not less than 25 percent of the cross-sectional area of the related feeder. A minimum size of 1/4 inch by 2 inches is required.


3.1 SYSTEM GROUND

A. System Neutral. Where a system neutral is used, ground the system neutral as required by NEC Article 250. Ground the system neutral only at the point of service and isolate it from ground at all other points in the system.

B. Separately Derived Systems. Solidly ground neutrals of separately derived systems such as transformers, etc., in accordance with NEC 250-26, whether neutrals are actually installed or not.

C. Size. Size the system grounding electrode conductors to comply with NEC Table 250-94, unless shown larger.

D. Testing. Test the completed grounding system. If the resistance of the grounding system is greater than 5 ohms, add ground rods to attain 5 ohms.

3.2 EQUIPMENT GROUND

A. Raceway Systems and Equipment Enclosures.

1. Ground cabinets, junction boxes, outlet boxes, motors, controllers, raceways, fittings, switchgear, transformer enclosures, other electrical equipment and metallic enclosures. Ground equipment and enclosures to the continuous-grounded, metallic raceway system in addition to any other specific grounding shown. 2. Provide bonding jumpers and ground wire throughout to ensure electrical continuity of the grounding system. 3. Provide grounding-type insulated bushings for metal conduits 1-1/2 inches and larger terminating in equipment enclosures containing a ground bus and connect the bushing to the ground bus. 4. Provide a green insulated equipment grounding conductor for each feeder and branch circuit.

B. Size. When grounding and bonding conductors are not sized on drawings, size the grounding conductors in accordance with NEC Table 250-95. Size bonding jumper so that minimum cross-sectional area is greater than or equal to that of the equivalent grounding conductor as determined from NEC Table 250-95.

END OF SECTION


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INSULATED CONDUCTORS 16120-1

SECTION 16120

INSULATED CONDUCTORS



This section includes the requirements for the provision of insulated conductors.


A. ANSI/UL 83 - Thermoplastic-Insulated Wires and Cables.

B. ANSI/UL 1277 - Electrical Power and Control Tray Cables with Optional Optical-Fiber Members.

C. ICEA S-61-402 (NEMA WC 5) - Thermoplastic-Insulated Wire and Cable for the Transmission and Distribution of Electrical Energy.

1.3 SUBMITTALS

A. Provide product data on the following:

1. 600-volt conductor, splicing and terminating materials.


2.1 IDENTIFICATION

Provide new insulated conductors marked according to NEC Article 310.

2.2 600-VOLT INSULATED CONDUCTORS

A. Size. As shown.

B. Construction.

1. Conductor. Soft-drawn, annealed copper. Stranded for No. 16 AWG and larger. 2. Insulation.

a. Unless otherwise noted on the drawings, use THWN for general wiring. b. Use Type shielded VFD 90ºC copper cable for load-side power cable routed between motor controllers (including variable frequency and soft start controllers) and motors where greater than 25 horsepower and not integrally furnished with motor (i.e. submersible pump motors).

C. Usage.

1. For general wiring use No. 12 minimum. 2. For field-installed control wiring use No. 14 or larger stranded conductors. 3. For tray cable (Type TC) provide a multi-conductor cable consisting of insulated conductors as described in the preceding paragraph with an overall outer sheath. Use a nonmetallic sheath


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that is moisture, sunlight and corrosion resistant and flame retardant, specifically approved for this purpose. 4. For analog cables provide individually shielded pairs or triads, as required for application, with overall shield and No. 16 or larger standard conductors.

D. Listing.

1. Single Conductor. UL 83. 2. Tray Cable. UL 1277.

2.3 SHIELDED VFD CABLES

A. Construction.

1. The cable shall be 600V/1000V rated, with stranded tinned copper conductors, shielded, suitable for use with Variable Frequency Drives. 2. The insulation shall be rated for 90 degrees Celsius Wet/Dry operating temperature. 3. Accessories (terminations) shall have ratings that are at least equal to those of the cable. 4. Cable shall be free from material and workmanship defects. 5. All cables shall be round. 6. Cable shall be suitable for use in wet/dry locations, indoors and outdoors, in cable trays, in conduits, trenches, and in underground ducts and direct burial.

B. Conductor. The conductor shall be annealed stranded tinned copper per ASTM B3, B8, and B33.

C. Insulation.

1. The insulation thickness shall have a minimum average wall thickness of 30 mils. The insulation material must be XLPE with a XHHW-2 listing per UL 44. Each insulated conductor shall be identified in accordance with ICEA Method 4 color coding. 2. The insulated conductors are to be cabled together with a minimum of one ground wire. The ground wire(s) are to have a minimum circular mil area equivalent to one circuit conductor. Fillers shall be included as necessary to make the cable round.

D. Shielding.

1. The cabled assembly shall be shielded using one of two methods: 2. Applying helically two 2-mil copper tapes. The shield shall provide 100% coverage over the assembly. 3. Applying a 80% minimum coverage tinned copper braid shield used in conjunction with an Aluminum Foil shield tape.

E. Jacket.

1. All cables shall have a continuous overall outer sheath of Polyvinyl Chloride (PVC), suitable for 90°C use. 2. The jacket shall be resistant to abrasion, rated for direct burial, sunlight resistant and flame resistant in accordance with UL 1277.


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3.1 INSTALLATION

A. Protection. Unless otherwise indicated, mechanically protect conductors for systems by installing in raceways. Do not install the conductors until raceway system is complete and properly cleaned. Use Polywater J cable lubricant when pulling conductors. Do not bend any conductor either permanently or temporarily during installation to radii less than four times the outer diameter of 600-volt insulated conductors. Do not exceed manufacturer’s recommended values for maximum pulling tension.

B. Splices and Terminations. Use pressure-type lugs or connectors for terminations or splices of all stranded conductors. Use ring-tongue type terminators on all control wiring. Make grounding (earth) conductor approximately 2 inches longer than the ungrounded (phase) conductors at both ends. Refer to Section 16060.

C. Appearance. Neatly and securely bundle or cable all conductors in an enclosure using nylon straps with a locking hub or head on one end and a taper on the other.

3.2 600-VOLT INSULATED CONDUCTORS

A. Size. Install conductor sizes as indicated. Provide No. 10 AWG conductor for the entire circuit length for single-phase, 20-ampere circuits for which the distance from panelboard to the last outlet is more than 100 feet for 120-volt circuits or 200 feet for 277-volt circuits.

B. Home Runs. Except where specifically indicated, provide branch circuit home runs with not more than two different line conductors and a common neutral in a single raceway for 3-wire, single-phase systems, nor more than three different line conductors and a common neutral in a single raceway for 4-wire, 3-phase systems. Use home run circuit numbers as indicated for panelboard connections.

C. Color Code. Use factory-colored insulated conductors for No. 10 and smaller conductors and color code larger insulated conductors with an approved field-applied tape. Use different colors for control wiring. Follow the color scheme below.

Line 240/120 208/120 480/277

A or L1 Black Black Brown B or L2 Red Red Orange C or L3 Orange Blue Yellow Neutral White White Gray Ground Green Green Green Switch Leg Pink Pink Pink

Where more than one conductor of the same phase or more than one neutral conductor occur at the same outlet or junction box, these conductors shall be identifiable from each other by use of stripes or distinguishing markings.

D. Field Testing. Insulation resistance of all conductors shall be tested. Each conductor shall have its insulation resistance tested after the installation is completed and all splices, taps and connections are made except connection to or into its source and point (or points) of termination. Insulation resistance of conductors which are to operate at 600 volts or less shall be tested by using a Biddle Megger of not less than 1000 volts d-c. Insulation resistance of conductors rated at 600 volts shall be free of shorts and grounds and have a minimum resistance phase-to-phase and phase-to-ground of at least 10 megohms.


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Conductors that do not exceed insulation resistance values listed above shall be removed at Contractor’s expense and replaced and test repeated. The Contractor shall furnish all instruments and personnel required for tests, shall tabulate readings observed, and shall forward copies of the test readings to the Owner in accordance with Section 16050. These test reports shall identify each conductor tested, date and time of test and weather conditions. Each test shall be signed by the party making the test.

END OF SECTION


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RACEWAYS 16130-1

SECTION 16130

RACEWAYS



This section includes the requirements for the provision of electrical raceway systems.

A. Conduit.

1. Rigid metal conduit. 2. PVC-coated rigid metal conduit. 3. Rigid nonmetallic conduit. 4. Liquid-tight flexible metal conduit.

B. Wireways.

C. Cable Tray.

D. Underground Duct Bank as specified in Section 02581.


A. ANSI C80.1 – Rigid Steel Conduit – Zinc-Coated

B. ANSI/UL 360 - Liquid-tight Flexible Steel Conduit.

C. ANSI/UL 467 - Electrical Grounding and Bonding Equipment.

D. ANSI/UL 651 - Schedule 40 and 80 Rigid PVC Conduit.

E. ANSI/UL 870 - Wireways, Auxiliary Gutters and Associated Fittings.

F. NEMA VE 1 - Metallic Cable Tray Systems.

1.3 SUBITTALS

Submit product data in accordance with Section 01330.


2.1 CONDUIT AND FITTINGS

A. Rigid Metal Conduit (RMC).

1. Conduit. Rigid hot-dipped galvanized steel (RGS) conduit with zinc-coated trheads and outer coating of zinc chromate. 2. Fittings. Threaded steel.


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RACEWAYS 16130-2

B. Rigid Nonmetallic Conduit.

1. Conduit. Schedule 40 and 80 polyvinyl chloride (PVC). 2. Fittings. Solvent weld socket type. 3. Bodies. Form 8.

C. PVC-Coated Rigid Metal Conduit.

1. Conduit. Same as rigid metal conduit plus a factory-applied, 40-mil-thick covering of polyvinyl chloride (PVC) bonded to the metal.. 2. Fittings. Same as rigid metal conduit fittings plus a factory-applied, 40-mil-thick covering of PVC bonded to the metal. 3. Bodies. Form 8. 4. Training. Schedule and provide “hands-on” training for installing personnel on proper preparation, installation and touch-up.

D. Liquid-tight Flexible Steel Conduit.

1. Conduit. Spiral-wound, square-locked, hot-dipped galvanized steel strip plus a bonded outer jacket of PVC. 2. Fittings. Compression type, malleable iron, with insulated throat, either cadmium plated or hot-dipped galvanized.

2.2 WIREWAYS

A. Material. Not less than 16-gauge thickness.

B. Dimensions. Cross section dimensions not less than 4 inches by 4 inches.

C. Type.

1. Indoor non-corrosive areas. NEMA 1, painted steel. 2. Indoor corrosive and outdoor areas. NEMA 4X, 316 stainless steel.

2.3 CABLE TRAY AND FITTINGS

A. Material.

1. In dry wells and non-corrosive areas. Aluminum alloy 6063 with fasteners of aluminum alloy 2024.

2. In wet-wells and corrosive areas. Polyester reinforced fiberglass with fasteners of 316 stainless steel.

B. Dimensions. (Exceptions noted on drawings.)

1. Depth: four inches, minimum inside depth. 2. Width: as shown on the drawings. 3. Radius: as determined by cable bending requirements.

C. Type. Ladder, with six-inch rung spacing.


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RACEWAYS 16130-3


3.1 CONDUIT AND FITTINGS

A. Minimum Trade Size.

1. Above Grade. ¾ inch. 2. Below Grade. 1 inch.

B. Types According to Use. Use rigid metal conduit (RMC) throughout the project except as specified below.

1. Use Schedule 80 PVC for above grade interior conduit at the following areas: a. Chlorine rooms. b. Phosphate rooms.

2. PVC-coated RMC or rigid nonmetallic conduit 1 inch and smaller may be embedded in slabs if the slab thickness is a minimum of 5 inches thick. Conduit placement shall not impair the slab’s structural integrity. 3. Use PVC-coated RMC or rigid nonmetallic conduit encased in concrete, in accodance with Section 02581, with minimum 3-inch-thick walls, for conductors installed below grade at a minimum depth of 18 inches to top of conduit. All horizontal to vertical transitions shall be made using PVC–coated RMC elbows and PVC-coated RMC conduit stub-ups. 4. Use direct-buried PVC conduit for conductors installed below foundations. All horizontal to vertical transitions shall be made using PVC–coated RMC elbows and PVC–coated RMC conduit stub-ups. 5. Do not allow RMC to make direct contact with concrete or earth. 6. Connect all electrical equipment subject to vibration or movement with liquid-tight flexible metal conduit 24 inches minimum length. 7. Chain-Hung Fixtures. Provide liquid–tight flexible metal conduit from a junction box directly above the fixture. Conduit length shall be such that the fixture weight is not borne by the conduit and does not cause excessive sag. 8. Transitions.

a. Where rigid nonmetallic conduit is used in concrete encasement or under concrete slabs, a conversion to PVC–coated RMC shall be made at least 3 feet before the run exits the encasement or slab cover. b. For below-grade to above-grade locations, extend concrete encasement around conduit 4 inches above finished grade and slope top away from conduit with a 6-inch-per-foot slope. This provision does not apply for conduits extending into pad-mounted or floor-mounted equipment.

C. Preparation. Place sleeves in walls and floor slabs for the free passage of cables or conduits. Set sleeves in place a sufficient time ahead of concrete placement so as not to delay the work. Seal all openings and voids around sleeves through floors and walls. Be sure that plugs or caps are installed before concrete placement begins.

D. Installation Requirements.

1. Metallic conduits must be continuous between enclosures such as outlet, junction and pull boxes, panels, cabinets, motor control centers, etc. The conduit must enter and be secured to enclosures so that each system is electrically continuous throughout. Where knockouts are used, provide double locknuts, one on each side. For RMC, provide nonmetallic insulating bushings for conductor protection. Where conduits 1-1/2 inches and larger terminate in equipment having a


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RACEWAYS 16130-4

ground bus, such as in switchgear, motor control centers and panelboards, provide conduit with an insulated grounding bushing and a suitable grounding conductor terminated at the ground bus. 2. Have rigid nonmetallic conduit adequately solvent welded at joints to form a tight, waterproof connection. 3. Run concealed conduit as directly and with the largest radius bends as possible. Run exposed conduit parallel or at right angles to building or other construction lines in a neat and orderly manner. Conceal conduit in finished areas. Unless otherwise noted, remaining conduit may be exposed. Provide chrome-plated floor and ceiling plates around conduits exposed to view and passing through walls, floors, partitions, or ceilings in finished areas. Select properly sized plates to fit the conduit when securely locked in place.

E. Installation Methods.

1. Install each entire conduit system complete before pulling in any conductors. Clean the interior of every run of conduit before pulling in conductors to guard against obstructions and conduit omissions. 2. Cut all joints square, then thread and ream smooth. 3. Make bends with standard ells or conduit bent in accordance with the NEC. Make field bends using equipment designed for the particular conduit material and size involved. Bends must be free from dents or flattening. Use no more than the equivalent of four 90-degree bends in any run between terminals and cabinets, or between outlets and junction boxes or pull boxes. 4. Conduit bodies may be used in lieu of conduit ells where ease of installation and appearance warrants their use. Conduit bodies larger than 1 inch may be used only where approved. 5. Securely fasten and support conduit to structure or metal framing using hot-dipped galvanized, malleable iron pipe straps or other approved means. Wires of any type may not be used for securing conduits. Branch circuit raceways which are 1 inch or smaller may be attached to wall studs by use of manufactured clips. 6. Provide a No. 30 nylon pulling line in conduits in which wiring is not installed under this work. Identify both ends of the line by means of labels or tags reading “Pulling Line - Telephone,” etc. 7. Suitably cap conduit during construction to avoid water, dirt and trash entrance. 8. Use expansion-deflection fittings on conduit crossing structural expansion joints and on exposed conduit runs where necessary. Provide bonding jumpers across fittings in metal raceway systems. 9. With a coupling, terminate concealed conduit for future use at structural surfaces. Install a pipe plug flush with the surface. 10. Openings around electrical penetrations of fire-resistance rated walls, partitions, floors or ceilings shall be firestopped to maintain the fire resistance rating using approved methods.

3.2 WIREWAYS

Install wireways, where shown, according to NEC Article 362.

3.3 CABLE TRAY

Install cable trays, where shown, according to NEC Article 318. Install cable trays in accordance with manufacturer’s recommendations. Unless otherwise shown, support trays on 10-foot centers and as further recommended in NEMA Standard VE-1. Provide “Caution - Do Not Use as Walkway” signs suitably displayed at places to be designated by the Owner’s representative.


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RACEWAYS 16130-5

END OF SECTION


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RACEWAYS 16130-6



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BOXES 16135-1

SECTION 16135

BOXES



This section specifies the furnishing and installation of outlet boxes, floor boxes, junction boxes, and pull boxes.


A. ANSI/NEMA Publication No. OS 1 - Sheet-steel Outlet Boxes, Device Boxes, Covers and Box Supports.

B. ANSI/UL 514A - Metallic Outlet Boxes.

C. ANSI/UL 514B - Fittings for Conduit and Outlet Boxes.

1.3 SUBMITTALS

Provide product data in accordance with Section 01330..


2.1 OUTLET BOXES

A. Exposed Device Boxes. Provide PVC-coated FS or FD cast aluminum boxes for surface mounting in corrosive areas. Provide cast aluminum boxes for surface mounting in areas having exposed RAC.

B. Masonry Boxes. Provide galvanized steel, 3-1/2-inch deep, masonry boxes for all devices installed in masonry walls.

C. Switch Boxes. Not permitted.

D. Listing. UL 514.

2.2 JUNCTION, PULL AND SPLICE BOXES

A. Construction. Provide 316 stainless steel boxes conforming to NEC Article 370.

B. Interior Spaces. Provide NEMA 1 type boxes at least 4 inches deep.

C. Exterior Spaces. Provide NEMA 4X type boxes at least 4 inches deep.

D. Embedded. Provide NEMA 4 cast iron type with flush flanged cover when cast in concrete.

E. Listing. UL 514.


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BOXES 16135-2


3.1 OUTLET BOXES

A. Fixture Boxes. Where boxes for suspended lighting fixtures are attached to and supported from suspended ceilings, adequately distribute the load over the ceiling support members.

B. Mounting Height. Mounting height of a wall-mounted outlet box means the height from finished floor to horizontal center line of the cover plate. Where outlets are indicated adjacent to each other, mount these outlets in a symmetrical pattern with all tops at the same elevation. Where outlets are indicated adjacent, but with different mounting heights, line up outlets to form a symmetrical vertical pattern on the wall. Verify the final location of each outlet with Owner's representative before rough-in. Remove and relocate any outlet box placed in an unsuitable location.

C. Box Openings. Provide only the conduit openings necessary to accommodate the conduits at the individual location.

3.2 JUNCTION AND PULL BOXES

A. Installation. Install boxes as required to facilitate cable installation in raceway systems. Generally provide boxes in conduit runs of more than 100 feet or as required in Section 16110.

B. Covers. Provide boxes so that covers are readily accessible and easily removable after completion of the installation. Include suitable access doors for boxes above inaccessible ceilings. Select a practical size for each box and cover.

END OF SECTION


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WIRING DEVICES 16140-1

SECTION 16140

WIRING DEVICES



This section specifies the furnishing and installation of wiring devices and device plates.


A. Americans with Disabilities Act (ADA).

B. ANSI/UL 20 - General-Use Snap Switches.

C. ANSI/UL 498 - Attachment Plugs and Receptacles.

D. ANSI/UL 943 - Ground Fault Circuit Interrupters.

E. NEMA WD 1 - General Requirements for Wiring Devices.

1.3 SUBMITTALS

Provide product data on wiring devices and plates in accordance with Section 01330.


2.1 WALL SWITCHES

A. Type. Quiet type, back and side wired switches as shown.

B. Rating. 20 amperes, 120/277 volts.

C. Listing. UL 20 and Federal Specification W-S-896.


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D. Acceptable Manufacturers. The following designations are for brown devices; provide devices in the color specified in Article 2.4.

Type Arrow Hart Bryant GE Hubbell

S 1991 4901 5951 HBL1221 S2 1992 4902 5952 HBL1222 S3 1993 4903 5953 HBL1223 S4 1994 4904 5954 HBL1224 SK(1) L L OLG L SP(2) PL PLR120 SP121-8G PL

(1) Key operated switch: add the indicated suffix to the above designations. (2) Switch with red pilot light: add the indicated suffix to the above designations. (Not available in S4.)

2.2 RECEPTACLES

A. Type. Back and side wired receptacles.

B. Rating. Scheduled on drawings.

C. Listing. UL 498 and Federal Specification W-C-596.

D. Acceptable Manufacturers. The following designations are for brown devices; provide devices in the color specified in Article 2.4.

NEMA Config.

Arrow Hart Bryant GE Hubbell

5-15R 5262 5262 5262-1 5262 6-15R 5662 5662 5662-1 5662 5-20R 5362 5362 5362-1 5362 6-20R 5462 5462 5462-1 5462 14-20R 5759 C 1420 8410 15-20R 5781 C 1520 8420 5-30R 5716N 9530-FR 4138-3 9308 6-30R 5700N 9630-FR 4139-3 9330 14-30R 5744N 9430-FR 4191-3 9430A 15-30R 8430N 8430-FR 1530-3 8430A GFCI GF8300 GFR83FT GFR8300 GF-8300

2.3 DEVICE PLATES

A. Finished Spaces. Use 302 stainless steel (18 percent chromium, 8 percent nickel) (9300 series of the device manufacturers listed above.

B. Exposed Boxes in Dry Interior Spaces. Make plates of heavy cadmium-plated sheet steel. Edges of plates must be flush with edges of boxes.


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C. Hose-down and Exterior Areas. Use weatherproof device plates. Provide enclosure with gasketed cover for protection of device and meeting the requirements of NEC-410-57b.

D. Acceptable Manufacturer. TayMac No. 71204 or approved substitution.

2.4 DEVICE COLOR

Use wiring devices in ivory for non-finished and light finished walls. Use wiring devices in brown for dark finished walls.


3.1 DEVICE COORDINATION

Where items of equipment are provided under other sections of this specification or by the Owner, provide a compatible receptacle for the cap or plug and cord of the equipment.

3.2 WALL SWITCHES

A. Location. Set wall switches in a suitable outlet box centered at the height of 44 inches from the floor, except as otherwise shown on the drawings. Install switch on the strike side of the door as finally hung.

B. Position. Install wall switches in a uniform position so the same direction of operation will open and close the circuits throughout the job, generally up for the ON position.

3.3 RECEPTACLES

Mount receptacles vertically with the ground on top in a suitable steel outlet box centered at the height of 18 inches from the floor, except as otherwise shown on the drawings. For horizontally mounted receptacles, ground should be on left. Reasonable changes in receptacle locations may be directed without change in the contract sum.

3.4 DEVICE PLATES

A. Type. Provide device plates for each outlet of the type required for service and device involved.

B. Ganged Devices. Mount ganged devices under a single, one-piece, device plate.

C. Engraving. Engrave plates with 1/8-inch-high black letters, if designated for engraving.

3.5 WIRING DEVICES

Install wiring devices in accordance with applicable requirements of the NEC, NEMA, ANSI, and the product manufacturer recommendations. Provide pig-tail connection to devices with down-stream devices. Do not feed through devices to connect to down-stream devices.

END OF SECTION


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TIME SWITCHES 16145-1

SECTION 16145

TIME SWITCHES



This section includes the requirements for the provision of electronic-type individually enclosed time switches.


A. UL 916 - Energy Management Equipment.

B. UL 917 - Clock-Operated Switches.

1.3 SUBMITTALS



2.1 MANUFACTURERS

Tork, Grasslin, Intermatic, Paragon, Zenith.

2.2 TYPE

Provide 7-day calendar electronic-type time switches powered by a 120-volt, 60-hertz power supply. Use units capable of being programmed for up to six different operations each day of the week, with an operating trip accuracy equivalent to line frequency and a minimum of one minute between an on and off operation.

2.3 CONTACTS

Provide double-pole, double-throw contacts rated 240 volts, 30 amperes per pole inductive.

2.4 ENCLOSURE

Supply each time switch in a lockable NEMA 4X enclosure suitable for surface mounting.

2.5 LOR SWITCH

Include a cover-mounted Local-Off –Remote (LOR) selector switch for each circuit. Wire LOR switch to permit selecting the mode of operation of the controlled equipment without changing the programmed operation of the time switch. Provide separate pole for each ungrounded conductor in each circuit.


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TIME SWITCHES 16145-2

2.6 RESERVE POWER

Use units with field replaceable batteries with a minimum 24-hour backup capability and minimum 3-year replacement interval. Provide a battery recharge feature which operates on power restoration.

2.7 PHOTOCELL

Provide unit suitable for connection of a photocell input to operate contacts in response to ambient light levels. Timer unit shall be capable of overriding photocell input, to allow control by both photocell and timer.

2.8 LISTING

UL 916 (electronic timers).


3.1 INSTALLATION

A. Install time switches in locations as shown and as recommended by the manufacturer. Synchronize all time switches and set on and off trippers as directed by the Owner.

B. Install photocell on building roof facing north.

END OF SECTION


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METAL FRAMING 16170-1

SECTION 16170

METAL FRAMING



This section includes the requirements for the provision and installation of metal framing, including channels, fittings, clamps, hardware, electrical accessories, and brackets.


NEMA ML 1 – Metal Framing.

1.3 SUBMITTALS



2.1 CHANNELS, FITTINGS, CLAMPS, ELECTRICAL ACCESSORIES, AND BRACKETS

A. Corrosive Areas. 316 stainless steel with 316 stainless steel or PVC-coated steel hardware. Galvanized hardware is not acceptable. Refer to Section 16130 for corrosive area locations.

B. Non-corrosive areas. Aluminum with aluminum hardware.

C. Fabricate threaded fasteners of Type 316 stainless steel.

2.2 SIZES

Provide channels fabricated from not less than 12 gauge thickness, 1-5/8 inches wide, and not less than 1-5/8 inches deep.


B-Line Systems, Inc.; Elcen Metal Products Company; Electrical Products Division, Midland-Ross Corporation; Metal Products Division, U.S. Gypsum Company; Power Strut; Unistrut.


3.1 SUPPORTS

Provide metal framing to support wall-mounted equipment, wall-mounted raceways, and ceiling-hung raceways.

3.2 ANCHOR BOLTS


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METAL FRAMING 16170-2

A. Use 1/2-inch diameter by 3 inches long Type 316 stainless steel expansion bolts to attach framing to concrete.

B. Space bolts a maximum of 24 inches on center, with not less than two bolts per piece of framing.

END OF SECTION


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MISCELLANEOUS EQUIPMENT 16191-1

SECTION 16191

MISCELLANEOUS EQUIPMENT



This section includes the requirements for the provision and installation of all miscellaneous equipment as shown on the Drawings and as specified herein.


Equipment enclosures shall have NEMA ratings suitable for the location in which they are installed, as specified in Division 16.

1.3 SUBMITTALS



2.1 MATERIALS

A. Manual Motor Starters.

1. Manual starters shall be suitable for the voltage and number of phase shown on the Drawings and shall be non-reversing, reversing or two speed type as shown on the Drawings. NEMA sizes shall be as required for the horsepowers shown on the Drawings. Manual starters shall have motor overload protection in each phase. 2. NEMA 4 enclosures shall be stainless steel. 3. NEMA 4X enclosures shall be stainless steel. 4. NEMA 7 enclosures shall be copper free cast aluminum. 5. Manual motor starters shall be as manufactured by General Electric.

B. Corrosion Inhibitors.

1. All equipment enclosures, terminal boxes, etc, located in a NEMA 4X rated area (where shown on the Drawings) that contains electrical or electronic equipment or terminal strips shall be furnished with an internally-mounted, chemically-treated corrosion inhibitor pad.

2. The corrosion inhibitor pads shall be as manufactured by Hoffman Engineering Co., 3M or equal.

C. Equipment Mounting Stands.

1. Equipment mounting stands shall be custom fabricated from 1/4-in steel plate and 4-in steel channel, as shown on the Drawings. 2. Hot dip galvanizing shall conform to the requirements of Division 5.


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MISCELLANEOUS EQUIPMENT 16191-2


3.1 INSTALLATION

A. Mounting Stands. Field-mounted disconnects, pushbutton control stations, etc, shall be mounted on steel stands as shown on the Drawings. Where clearance requirements for stands may not be maintained, the ENGINEER may direct equipment to be wall-mounted adjacent to the drive, but in no case shall the distance from the drive motor to the control station exceed 3-ft.

END OF SECTION


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AC ELECTRIC MOTORS – 100HP AND BELOW 16222-1

SECTION 16222

AC ELECTRIC MOTORS – 100HP AND BELOW



A. Equipment. This section specifies general requirements for 1-phase and 3-phase electric motors with NEMA frame machines sized through 100 horsepower. Unless otherwise specified, provide motors meeting the basic requirements for general-purpose alternating current motors, as defined in ANSI/NEMA MG 1-1.05.

B. Unit Responsibility. Motors are furnished under other sections of this specification as a part of the driven equipment. The Contractor is responsible for all coordination between the various components and for the warranty.

C. Statement. The Contractor shall be responsible for obtaining information on the existing pump/motor from the pump manufacturer. Contractor shall coordinate the motor being furnished with the existing pump manufacturer for torque characteristics and bearing size for the pumping application. Contractor shall furnish a written statement that the motor being furnished has been coordinated with the pump manufacturer.

D. Exceptions. Exceptions to this section are indicated either in the various sections that specify motor-driven equipment or on the drawings.


A. ANSI/IEEE 117 - Standard Test Procedure for Evaluation of Systems of Insulating Materials for Random Wound AC Electric Machinery.

B. ANSI/NEMA MG 1 - Motors and Generators.

C. ANSI/NEMA MG 2 - Safety Standard for Construction and Guide for Selection, Installation and Use of Electric Motors.

D. ANSI/UL 674 - Electric Motors and Generators for Use in Hazardous (Classified) Locations.

E. ANSI/UL 1004 - Electric Motors.

1.3 SUBMITTALS

A. Provide the following information in accordance with Section 01330:

1. Manufacturer. 2. Rated full load horsepower. 3. Rated volts. 4. Number of phases. 5. Frequency in hertz. 6. Full load amperes (FLA). 7. Locked rotor amperes (LRA) at rated voltage or NEMA code letter.


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8. Nominal speed at full load (rpm). 9. Service factor. 10. NEMA design letter. 11. NEMA machine type (ODP, WP-I, TEFC, etc.).

B. For motors 1 horsepower and larger, include the following additional information:

1. NEMA frame size. 2. NEMA insulation system classification. For motors required to be installed outdoors, include information showing compliance with the intent of paragraph 2.3C. 3. Maximum ambient temperature for which motor is designed. 4. Time rating. 5. Bearing type. 6. Efficiency at full load.

C. For motors 20 horsepower and larger, include the following additional information:

1. No load amperes. 2. Safe stall time. 3. Efficiency at 1/2 and 3/4 load. 4. Power factor at no load, 1/2, 3/4 and full load. 5. Motor manufacturer's recommended maximum power factor correction capacitor (kvar) that can safely be switched with the motor. 6. Expected value of corrected power factor at no load, 1/2, 3/4 and full load. 7. Full load amperes with corrected power factor. 8. Maximum guaranteed slip at full load.

D. For motors with space heaters, include space heater voltage and wattage.


2.1 RATING

A. Speed and Size. Speed and approximate horsepower ratings are specified in the driven equipment specification sections or are indicated on the drawings. Furnish motors sufficiently sized for the particular application and with full-load rating not less than required by the driven equipment at specified capacity. Size motors so as not to overload at any point throughout the normal operating range.

B. Voltage.

1. Single phase: 115 volts for 120-volt nominal system voltage. 2. Three phase: 200 volts for 208-volt nominal system voltage. 3. Three phase: 230 volts for 240-volt nominal system voltage. 4. Three phase: 230/460 volts for 240/480-volt nominal system voltage. 5. Three phase: 460 volts for 480-volt nominal system voltage.

C. Frequency. 60 hertz.

D. Service Factor. According to NEMA MG 1-12.47 but not less than 1.15.


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E. Acceleration Time. For integral horsepower motors, if the calculated acceleration time of the combined motor and driven load exceeds 3 seconds at 90 percent of rated voltage, request review by the Owner's representative. Do not proceed with manufacturing without approval.

F. Safe Stall Time. For integral horsepower motors, if the safe stall time is less than 15 seconds when hot, request review by the Owner's representative. Do not proceed with manufacturing without specific approval.

G. Efficiency. Provide energy-efficient motors meeting the requirements of NEMA MG 1-12.55A, Table 12Y and MG 1.41.3. Efficiency to be determined by testing in accordance with NEMA MG 112.53 using IEEE 112A - Method B.

2.2 DESIGN TYPE

A. Motors Smaller than 1/6 Horsepower. Provide single-phase squirrel-cage induction motors with integral thermal protectors.

B. Motors 1/6 through 1/2 Horsepower. Provide single-phase NEMA Design Letter N, squirrel-cage induction motors.

C. Motors Larger than 1/2 Horsepower. Provide 3-phase, NEMA Design Letter B, squirrel-cage induction motors.

D. Motors Used with Variable Frequency Drives. Provide 3-phase, NEMA Design Letter B, squirrel-cage induction motors, inverter rated. Motor manufacturer shall provide a written statement that the motor is compatible with VFDs.

2.3 MOTOR INSULATION

A. Class. Use a Class F insulation with Class B Temperature rise system meeting the requirements of NEMA MG 1-1.65 and made of nonhygroscopic materials.

B. Outdoor Suitability. Where motors must be suitable for outdoor installation, the insulation must withstand 1 full week (168 hours) of testing in a chamber maintained at 100 percent relative humidity and 40 C ambient temperature. Immediately after the test period, the insulation system must have a minimum resistance of 1.5 megohms. In addition, the inside circumference of the stator and the outside circumference of the rotor and shaft must be coated with the same moisture-resistant insulation.

2.4 LEADS

For motor leads, use not less than ASTM B 173, Class G, stranded copper conductors with insulation the same as or better than specified in the preceding Motor Insulation paragraph. Provide permanent identification numbers on leads according to NEMA MG 1-2.02. Use crimp-on, solderless copper terminals on leads and place heat-shrink insulation sleeves or covers between leads and terminals.

2.5 ENCLOSURE

A. Indoors. Totally enclosed, fan cooled (TEFC). Use steel frame for motors smaller than 3/4 horsepower, and cast-iron frame for motors 3/4 horsepower and larger.

2.6 BEARINGS


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A. Motors Smaller than 1/6 Horsepower. Motor manufacturer's standard bearing is acceptable.

B. Motors 1/6 Horsepower and Larger.

1. Antifriction. Supply motors with grease-lubricated antifriction ball bearings conservatively rated for long life under the total radial and thrust loads produced by the actual combination of motor-driven equipment. Provide each motor with suitable lubrication fittings and pressure relief devices suitable for in-service lubrication. 2. Oil Lubricated. If the driven equipment section specifies oil-lubricated bearings for motors, include a suitable sight gauge on each bearing with maximum and minimum levels clearly indicated.

2.7 HARDWARE

Use structural bolts, washers, nuts, pins, and similar items manufactured of high-strength steel. Use only hexagon-head bolts and hexagon nuts. Use corrosion-resistant materials or protect hardware from corrosion by either hot-dip galvanizing, chrome plating or cadmium plating.

2.8 NAMEPLATES

A. Main Nameplate. Provide each motor with a stainless steel nameplate meeting the requirements of NEMA MG 1-10.38, and the National Electrical Code, Section 430-7. Energy-efficient motors shall be identified in accordance with MG-1-12.54.2.

B. Heater Nameplate. When space heaters are furnished, include voltage and wattage on a suitable nameplate.

C. Bearings Nameplate. When bearings are oil lubricated, include oil type information on a suitable nameplate. Also, indicate bearing data if nonstandard.

D. Attachment. Attach the nameplates to the motor with stainless steel fastening pins or screws.

2.9 CONDUIT BOX

For each motor not supplied with a cord and plug, provide a conduit box suitably sized for the motor lead terminations, in accordance with the National Electrical Code, Section 430-12. Include a grounding lug for motors 1/6 horsepower and larger. Supply a gasket suitable for the motor enclosure type and application.

2.10 PAINT

Manufacturer's standard shop paints for prime and finish coats are acceptable.

2.11 NOISE

Provide integral horsepower motors with overall sound power levels meeting the requirements of MG 1-12.49.


3.1 INSTALLATION


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Properly install and align motors in the locations shown, except motors which are factory mounted on the driven equipment. Use crimp-on, solderless copper terminals on the branch circuit conductors. For motors 20 horsepower and larger, use 5300 series 3M motor lead splicing kit or approved equal. When the motor and equipment are installed, the nameplate must be in full view.

3.2 LARGER MOTORS

If a motor horsepower rating larger than indicated is offered as a substitute and accepted, provide required changes in size of conductors, conduits, motor controllers, overload relays, fuses, circuit breakers, switches and other related items at no change in the contract price.

3.3 FIELD TESTING

A. General. Provide all necessary instruments, labor and personnel required to perform motor inspection and testing.

B. Inspection. Inspect all motors for damage, moisture absorption, alignment, freedom of rotation, proper lubrication, oil leaks, phase identification and cleanliness, and report any abnormalities to Owner's representative before energizing.

C. Tests. All motors 20 horsepower and larger shall be megger tested, in accordance with IEEE Report No. 43, "Recommended Practices for Testing Insulation Resistance of Rotating Machinery," to determine insulation resistance. In addition, motor full load current and full load voltage shall be measured. Motor Test Report forms included at the end of this section shall be completed and submitted to the Owner's representative.

D. Energizing. After installation has been thoroughly checked and found to be in proper condition, with thermal overloads in motor controllers properly sized and all controls in place, energize the equipment at system voltage for operational testing.

END OF SECTION


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DATE _________________

SHEET ______ OF ______

MOTOR TEST REPORT

PROJECT NAME _____________________________________________

PROJECT NO. ________________________________________________

MOTOR MANUFACTURER ____________________________________

MOTOR DESIGNATION __________________________, LOCATION ______________________________

HP _____________, FLA _____________, LRA _____________, NOMINAL VOLTAGE _______________

INSULATION CLASS _____________

SERVED FROM PANEL/MCC _____________

MEASURED CONDITIONS

TEMPERATURE: __________________�F

RELATIVE HUMIDITY: ______________%

CURRENT (AMPS): �A __________, �B __________, �C __________

VOLTAGE (VOLTS): �AB __________, �BC __________, �CA __________

�AN __________, �BN __________, �CN __________

INSULATION RESISTANCE:

�AB __________, �BC __________, �CA __________

�A-GND __________, �B-GND __________, �C-GND __________

STARTING TIME: __________ SECONDS, SAT __________ UNSAT __________

VIBRATION: SAT __________ UNSAT __________

BEARING TEMPERATURE: SAT __________ UNSAT __________


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PACKAGED ENGINE GENERATOR SYSTEMS 16230-1

SECTION 16230

PACKAGED ENGINE GENERATOR SYSTEMS



A. The Contractor shall furnish, install, and test weather-protective enclosed standby natural gas engine generator units skid mounted on steel structural base with vibration isolators, all in accordance with the requirements of the Contract Documents.

B. The Contractor shall furnish the engine generator unit complete with unit mounted generator control panel, automatic transfer switch (ATS), automatic electric starting and control equipment, exhaust silencer and piping, intake cleaner and piping, oil pumps, integral radiator, lubricating oil and engine jacket water heater, batteries and battery charger(s), instruments and auxiliary equipment necessary to make the unit completely automatic in starting, operating, and stopping in response to power requirements. The complete unit shall be covered by a comprehensive warranty.

1.2 SUBMITTALS

A. Submit the following information in accordance with Section 01330.

1. Engine Data. a. Manufacturer and model number. b. Rated capacity in horsepower (standby rating). c. Type of engine; aspiration and cooling system. d. Number of cycles and cylinders; speed in RPM. e. Piston displacement. f. Type and make of governor. g. Starting KVA; maximum voltage dip. h. Dimensions and weights. i. Air cooling requirements.

2. AC Generator Data. a. Manufacturer and model number. b. Rated capacity in kw (standby rating) at 0.8 power factor. c. Type of generator; construction. d. Voltage; phase, frequency, and connections. e. Insulation class; temperature rise. f. Efficiency and regulation. g. Starting KVA; maximum voltage dip. h. Dimensions and weights. i. Air cooling requirements.

B. The Contractor, in addition to, shall include the following information as part of the submittals:

1. Engine generator set plans and elevations or riser views showing entrance points for each of the interconnections required. 2. Engine generator/exciter control panel. 3. Fuel consumption rate curves at various loads. 4. Ventilation CFM requirements including allowable cooling fan pressure loss.


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5. Exhaust system and vibration isolation. 6. Battery charger, battery, and battery rack. 7. Remote radiator. 8. Actual electrical diagrams including schematic diagrams and interconnection wiring diagrams for all equipment to be provided. 9. Legends for all devices on all diagrams. 10. A certified performance rating from the engine manufacturer that the generator set when equipped with all auxiliary equipment as needed or specified shall have a minimum rating as specified herein when installed at the specified altitude. 11. Complete test specification detailing the testing procedure to be used to verify the performance of the equipment provided.

C. The Contractor shall submit eight (8) copies of the Operation and Maintenance manuals with each unit as follows:

1. Furnish eight identical sets of technical manuals when generator unit is delivered. Each set shall consist of one or more volumes, each of which shall be bound in a standard size, 3-ring loose-leaf, vinyl plastic hard cover binder suitable for bookshelf storage. Binder ring size shall not exceed 2.5 inches. 2. Technical manuals shall include operating and maintenance instructions as applicable, for each item of mechanical and electrical equipment, as follows:

a. Complete operating instructions, including location of controls, special tools, or other equipment required, related instrumentation, and other equipment needed for operation. b. Lubrication schedules. c. Preventive maintenance procedures and schedules. d. Parts lists, by generic title and identification number, complete with exploded views of each assembly. e. Disassembly and reassembly instructions. f. Name, location, and telephone number of nearest supplier and spare parts warehouse. g. Recommended troubleshooting and start-up procedures.

D. The Contractor shall submit “As-Built” electrical drawings including interconnection, schematic and wiring diagrams.


A. General. The engine-generator unit shall be the product of a single United States manufacturer that has been regularly engaged for a minimum of 15 years in the production, manufacturing and assembly in the United States of the type and size of equipment specified herein. All materials and parts in this unit shall be new and unused, of current manufacture, and of the highest grade, and free from all defects that may affect performance. To qualify as a manufacturer, the engine must be the principal item manufactured and the completed engine generator set shall be supplied by that manufacturer’s authorized dealers only.

B. Unit Responsibility. The engine-generator unit and all appurtenant equipment specified herein, and the drop-over enclosure shall be provided by a single manufacturer/vendor, establishing one source of responsibility for the equipment performance and assuring high standards of quality, coordination, reliability and service.

C. Factory Test. Prior to delivery at the job site, the engine generator unit and appurtenant equipment shall be tested at the manufacturer’s testing facility to verify that the equipment is free of any


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defects; to verify guaranteed performance, and to simulate automatic starting of the unit in conjunction with appurtenant equipment as specified herein.

1. The test for the generator shall be in accordance with IEEE Standard 115. The test shall show guaranteed performance of the equipment as required by the following tests, but not be limited to:

a. Insulation resistance and high pot test. b. Field winding polarity test. c. Voltage regulation from no load to full load.

2. The following information shall be recorded during the test: a. Temperature rise. b. Output frequency. c. Voltage and current at different loads. d. Fuel consumption rate. e. Oil and coolant temperatures and pressures.

3. The testing of the generator unit, complete with all auxiliaries, shall be for a period of 4-hour load test prior to shipment, including repeated automatic starts at least 2 hours at full load. Testing shall include block loading and unloading, using dry load banks at 25 percent, 50 percent, 75 percent and 100 percent of rated KW. The load bank shall be for unity power factor. The engine shall run in each step until temperature has stabilized and voltage and frequency variations at each step shall be measured. Certified test reports shall be furnished to the Engineer prior to shipment of the unit to the job site. Test report shall include temperature of each phase winding taken at 5 minute intervals during load run.

D. Warranty. Equipment furnished under this Section shall be guaranteed against defective parts and workmanship under the terms of the manufacturer’s and supplier’s standard warranty. In no event shall it be for a period of less than one (1) year from date of final acceptance of the system and shall include labor, materials and travel costs for necessary repairs at the job site.


2.1 MANUFACTURER

A. The acceptable manufacturer is Cummins Power Generation.

Cummins Southern Plains, LLC. 600 N. Watson Rd. Arlington, TX 76011 Attn: M. Scott Thomas, Application Engineering Manager 817-640-6885 Email: [email protected]

2.2 ENGINE

A. General.

1. Each engine shall be four stroke cycle, water cooled in-line or vee type spark-ignited natural gas generator, after cooled, and manufactured in the United States. It shall meet specifications when operating on Natural Gas. Block shall be of one piece design and cast of high tensile strength iron in the system manufacturer’s own foundry. Multiple blocks shall not be allowed. Counterboring for cylinder liners shall not be permitted. Crankshaft shall be a one piece forging with regrindable wear surfaces hardened through heat treat methods.


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2. The engine shall be equipped with lube oil, fuel and intake air filters, lube oil cooler engine driven battery charging alternator, service meter, gear driven water pump and jacket water heater.

B. Engine/Generator Control Panel.

1. The generator control panel shall be a unit mounted and shall have the following features: a. Engine controls and monitoring. b. Automatic/manual starts stop control. c. Engine control switch for off/reset, auto start, manual start, stop d. Emergency stop pushbutton.

1) Low oil pressure. 2) High coolant temperature. 3) Overcrank. 4) Overspeed. 5) Oil pressure. 6) Fuel pressure. 7) System DC volt. 8) Inlet air pressure (boost). 9) Engine speed and hours.

e. The engine generator control panel shall be the manufacturer’s premium control panel.

2. Starting Motor. A dc electric starting system including two starting motors with positive engagement drive shall be furnished. The motor voltage shall be as recommended by the engine manufacturer. 3. Batteries. One set of lead acid storage batteries set of the heavy-duty starting type shall be provided for each engine generator set. Battery voltage shall be 12 or 24 volt and compatible with the starting system. The battery set shall be rated no less than 220 ampere hours. Necessary cables and clamps for battery connection shall be provided. 4. Battery Racks. Battery racks shall be galvanized steel construction, conforming to NEC 480-7 with plastic insulating rails at all points of contact with the battery case. Racks shall contain any spillage or boil-over of electrolyte to prevent a direct path to ground. 5. Battery Charger. One (1) current limiting battery charger shall be furnished to automatically recharge batteries. Charger shall float at 2.17 volts per cell and equalize at 2.33 volts per cell. It shall include overload protection, silicone diode full wave rectifiers, voltage surge suppressor, DC voltmeter and fused ac input. AC input voltage shall be 120 volts, single phase. Amperage output shall be no less than 30 amperes. Charger shall be in NEMA 12 enclosure suitable for wall mounting and shall be UL listed. Charger shall locally indicate loss of AC power, low battery voltage, high DC charge and provide a common output alarm to the engine-generator control panel. 6. Pre-Alarm Sensors. Pre-alarm sensors shall be provided on the engine to provide signals to audible and visual alarm warning units of impeding fault conditions and provide audible alarm on fault shutdown. Sensors shall govern low oil pressure and high water temperature functions. Pre-alarm shall include low water level at radiator. 7. Provide pre-wired general alarm from C dry contacts which change state for all engine/generator pre-alarms, fault shutdown alarms, battery charger alarms and fuel tank alarms.

C. Governor.

1. The engine governor shall be an electronic governor capable of isochronous frequency regulation from no load to full load. 2. Governor shall maintain frequency regulation not to exceed 25% from no load to full load.


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D. Cooling system shall be unit mounted radiator cooled, closed circuit cooling rated for an ambient of 110 degrees F.

1. The system shall have ample capacity to permit up to 100 percent of full load operation at an ambient temperature of 100 degrees F at sustained operation. 2. The fan shall be of the pusher type. The radiator shall be provided with protecting stainless steel grille. 3. A 50 percent ethylene glycol coolant shall be provided.

E. Exhaust System. The engines shall be equipped with a dry, insulated, exhaust manifold as specified herein.

1. A single critical type silencer muffler companion flanges, and flexible braided stainless steel exhaust fittings properly sized shall be furnished according to manufacturer’s recommendations. Muffler mounting shall be for mounting in horizontal position. Silencer shall be standard steel. 2. Muffler and exhaust piping shall be sized to ensure that exhaust back pressure does not exceed the maximum specified by the engine manufacturer. Muffler shall have drain valve in silencer at the lowest point for condensation drain. 3. The exhaust system and exhaust silencer above flex connector shall be thermally insulated, aluminum jacketed.

F. Engine Jacket Water Heater.

1. Electric heater shall be installed on the engine, complete with thermostat control in the engine cooling water system to maintain at all times, while the engine is not in operation, a jacket water temperature of 100 degrees F to 140 degrees F. 2. The heater shall be 208 volt, three-phase. 3. Vee-type engine shall have one heater on each bank of cylinders. 4. The heater shall be an electric immersion or thermal circulation type.

G. Lubrication System.

1. The engine shall have a positive gear-type lubricating oil pump and a full flow lubricating oil filter system which shall filter all oil before it enters the main bearing galleries and other areas to be lubricated. 2. The crankcase shall have inspection cover plates to permit easy inspection and access to the oil pump and oil pump screen. 3. The oil filter system shall be engine-mounted, spin-on, cartridge type oil filter; oil filter shall not block access to engine inspection ports and essential piping.

H. Engine Base. The engine-generator unit(s) shall be mounted on a wide flange skid-type I-beam base to maintain engine alignment and provided with spring vibration isolators.

I. Fuel System Accessories. The fuel system shall be electronic unit injection type, and shall include, but not limited to, fuel strainers and injectors.

J. Pipe Connection. All pipe connections to the engine shall be made with flexible connectors of not less than 12 inches in length, with flanges or screwed ends, suitable for minimum 150 psig working pressure and 250 degrees F temperature.

K. Pressure and Temperature Electronic Sensors. Engine mounted pressure and temperature electronic sensors shall be direct continuous reading type with adjustable range and differential.


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1. Pressure sensors shall be provided for lube oil low alarm and shutdown. 2. Temperature switches shall be provided for jacket water temperature low alarm and high temperature shutdown, and lube oil high temperature alarm and shutdown. Level switch shall be provided to monitor jacket water level.

L. Engine Accessories. The following engine accessories shall be provided.

1. Guards. Guards shall be provided overall exposed moving parts as required by OSHA. 2. Oil Drip Pan. Provide No. 14 gage galvanized steel drip pan 1-inch deep. Drip pan shall be sized to cover the area beneath the engine.

M. Engine Manufacturer.

1. Cummins. 2. Approved Equal.

2.3 AC GENERATOR

A. Rating. Provide generators with ratings and supply voltage as shown on the drawings. The generator shall be standby rated as shown, with 130 degrees C rise over 40 degrees C ambient, 60 hertz at 1800 rpm with field windings braced for solid grounding. The rating shall be for continuous standby operation during interruption of the normal utility power.

B. Design. The generator shall be 4 pole rigidly coupled to the engine, permanently aligned and of drip proof construction. Bearings shall be shielded permanently lubricated ball bearings. The alternator shall be of the brushless revolving field type random wound or with permanent magnet exciter and sold state voltage regulator.

C. Materials. The generator shall have cast iron or fabricated steel frame. Windings shall have Class H insulation with Class F temperature rise per NEMA MG1-1.66, for both stator and rotor epoxy and vacuum pressure impregnated (VPI) with material that will not support fungus growth. Temperature rise at standby rated load shall not exceed 130 degrees C over 40 degrees C as per NEMA MG 1-22.40 definition.

D. Voltage Regulation. A unit mounted voltage regulator shall provide no more than .25 percent voltage regulation from no load to full rated load. Voltage adjustment shall be a minimum of ± 5 percent.

1. Voltage regulator shall be digital type, fully encapsulated. 2. Standard features shall include 3-phase RMS sensing, paralleling, adjustable underfrequency protection under/over voltage protection, rotating diode monitor, loss of sensing protection, loss of excitation protection, and over-excitation protection. 3. The voltage regulation system shall be insensitive to induced waveshape distortion from SCR or thyristor circuits such as those used in battery charging (ups) and motor speed control equipment loads or variable frequency drives (VFD). 4. Generator set shall be capable of safe stable operation with SCR loads of up to 30 percent of the units KVA rating without exceeding the temperature rise limits of the generator insulation system. 5. The digital voltage regulator shall have the following displays:

a. Frequency. b. Voltage. c. Current. d. Diagnostic status. e. Operating hours.


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E. Space Heater. Generator shall have a 120 volt, 60 hertz, single phase space heater to keep alternator dry. Heater shall automatically energize when generator unit is off and be thermostatically controlled to maintain a uniform temperature.

F. Terminal Box. All wiring points for remote interconnection between the generator unit and control panel shall be through a single junction box mounted on the generator set with numbered terminal strips for field wiring. Junction box shall have provision for bottom conduit entry.

G. Accessories. The generator shall have the following additional devices mounted on the unit: Lighting and surge protection consisting of one storm trapper high energy low voltage distribution class surge arrestor per phase shall be Cooper Power Systems ASZH480E101, or equal.

H. Provide 2000 AF/2000AT main generator circuit breaker in accordance with Section 16415 – Paragraph 2.7.

2.4 SOUND ATTENUATION HOUSING

A. Construction. Provide an overall housing with removable side panels and a hinged, padlockable meter panel door. Unitized construction between the stud and the acoustical enclosure. The maximum sound level measured one meter from the enclosure in free field conditions under full load shall not exceed 85 dBA.

B. Painting. Prime all exposed metal parts with a suitable rust inhibitor applied to the clean, bare metal followed by two coats of an epoxy paint.

C. Acoustical Treatment. Intake and exhaust silencers shall be provided at the ends of the skid.

D. Ventilation Fans. A ventilation fan or fans shall be provided in the enclosure. The fans shall provide the CFM requirements for the combustion air and for removing radiant heat from the generator and the engine and maintain a 30°F temperature rise in the enclosure. In addition to the static pressure requirements for the enclosure, the fans shall also be able to overcome an additional 3/8 inch of water in static pressure. All motor starters and associated control and wiring shall be included. Power for the fans shall be derived from the generator. The ventilation flow shall be from the generator end to the engine end. An acoustic treated duct shall be provided between the exhaust silencer and the louver in the wall.


3.1 INSTALLATION

A. The engine/generator unit, including all accessories, shall be installed in accordance with the manufacturer’s published recommendations. Start-up shall be provided by the manufacturer’s authorized field representative.

B. The complete engine/generator unit shall be anchored in place on a concrete pad with leveling channels.

C. It is the intent of these Specifications that the unit supplier shall furnish and install associated equipment and accessories, and furnish all the labor to make the system complete and operational.

3.2 FIELD TESTS


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A. Field test shall be conducted by the manufacturer’s authorized representative after installation to assure compliance with all operating requirements of the specifications.

B. Tests shall include, but not be limited to, a full rated power load test for a period of 4 hours using a reactive dry bank load cell to simulate the actual design loads as shown on the drawings.

C. All field tests shall be witnessed by the Engineer and Owner; test results all documented and submitted to the Engineer.

3.3 START-UP AND OPERATIONS INSTRUCTION

A. Upon completion of the installation and field tests, startup shall be performed in accordance with manufacturer’s published procedures.

B. Step-by-step detailed instructions of the operation of the unit(s) shall be furnished by the equipment supplier. The instructions shall include, but not be limited to, the following procedures:

1. Start up of the unit. 2. Normal shutdown of the unit. 3. Emergency shutdown of the unit.

C. The manufacturer’s representative shall conduct a total of three (3) eight (8) hour training sessions for the start-up and operations and maintenance of the engine generator unit, automatic transfer switch (ATS), and appurtenant equipment.

END OF SECTION


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DRY-TYPE TRANSFORMERS - 600 VOLT PRIMARY AND BELOW 16276-1

SECTION 16276

DRY-TYPE TRANSFORMERS - 600 VOLT PRIMARY AND BELOW



This section includes the requirements for the provision of dry-type transformers with 600 volt and below primary and rated 500 kVA and smaller.


Design, test, assemble and install in conformance to the latest edition of the following applicable industry standards.

A. ANSI/UL 506 - Specialty Transformers.

B. ANSI/UL 1561 - Dry-Type General Purpose and Power Transformers.

C. IEEE C57.94 - Recommended Practice for Installation, Application, Operation and Maintenance of Dry-Type General-Purpose Distribution and Power Transformers.

D. ANSI/NEMA ST 20 - Dry-Type Transformers for General Applications.

E. NFPA 70 - National Electrical Code (NEC).

1.3 SUBMITTALS

A. Submit the following information for each size and type of transformer being provided in accordance with Section 01330.

1. Manufacturer.

2. Rated kVA, number of phases and frequency.

3. Primary voltage and connections.

4. Secondary voltage and connections.

5. Number and percent taps.

6. Outline dimensions.

7. Total weight of unit.

B. Submit the following information for record purposes at closeout in accordance with Section 01800.


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1. O&M Manual. The manufacturer shall furnish with the submittal and with each unit delivered an equipment manual that details the installation, operation, recommended renewal parts list, and maintenance instructions for the specified unit.


2.1 MANUFACTURERS

A. Square D.

2.2 RATINGS

Required kVA, voltages, phases and winding configurations are indicated on the drawings. Transformers must be rated for 60 hertz operation, self-cooled NEMA Class AA and FA, and shall be listed under UL 506 or 1561.

2.3 COILS

A. Windings. Use copper wire (bar stock) for coil windings.

B. Taps. Furnish transformers with full load rated taps in the primary winding as follows:

KVA Rating Taps

3-15 kVA, single phase; 9-15 kVA, three phase

Two 5 percent taps below rated voltage

25-100 kVA, single phase; 30-300 kVA, three phase

Six 2-1/2 percent taps, four below and two above rated voltage

167-250 kVA, single phase; 500 kVA, three phase

Four 2-1/2 percent taps, two below and two above rated voltage

2.4 INSULATION

Provide a 220°C insulation system which is the manufacturer’s standard for a maximum 80°C rise over a 40°C ambient.

2.5 SOUND REQUIREMENTS

Average sound levels must not exceed the following values as measured in accordance with NEMA ST 20-4.12.

kVA dB

0-9 40 10-50 45

51-150 50 151-300 55 301-500 60


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2.6 CONSTRUCTION

A. Enclosure. Unless otherwise specified or indicated, install transformers in metal enclosures designed to provide air cooling and to prevent accidental contact with live conductors.

A. Enclosure. Install transformers with resin-encapsulated coils in totally-enclosed, non-ventilated metal enclosures designed to prevent accidental contact with live conductors.

B. Wiring Compartment. Locate the wiring compartment below the core and coil. Have the compartment cooled by air circulation or insulated from the core and coil with a suitable thermal barrier.

C. Grounding.

1. Ground the core of the transformer to the enclosure with a flexible grounding conductor sized according to NEC requirements. 2. Ground the transformer neutral in accordance with the NEC.

D. Mounting Brackets. Furnish mounting brackets, as required, for wall or structure mounting of transformers rated 45 kVA and less.


3.1 TAP SETTING

Select the appropriate tap setting on transformer so that the actual secondary voltage is + 1/2 of a tap span at full load. Record the transformer serial number, kVA rating, selected tap setting and secondary voltage readings. Submit copies of the record to the Architect/Engineer.

3.2 CABLE CONNECTIONS

Make transformer cable connections with compression-type lugs suitable for termination of 75°C rated conductors. Position lugs so that field connections and wiring will not be exposed to temperature above 75°C.

3.3 MOUNTING

A. Floor. Construct concrete pad for floor-mounted transformers in accordance with Section 16050, Electrical General Provisions. Maintain a minimum of 6 inches free air space between enclosure and walls.

B. Wall. Securely anchor wall mounting brackets to wall to provide adequate support.

C. Suspended. Suspend transformers from structure by means of trapeze hangers constructed of galvanized all-thread rods and metal framing channels. Make double-nut connections between rods and channels. Locate to provide adequate ventilation and accessibility.

D. Vibration Isolation. Mount transformers on vibration isolating pads suitable for isolating the transformer noise from the building structure.

1. For floor transformer installations, use one pad-type Korfund Elasto-Grip waffle, or accepted substitution, at each corner of the transformer, sized for load of 50 lbs./sq.in.


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2. For wall or ceiling hung transformer installations, use spring-type Korfund Series P, or accepted substitution. Provide sound pads at each corner of the transformer, sized for 1/2-inch deflection. 3. Verify removal of shipping brackets before transformer is energized.

E. Ventilation. Provide adequate clearance around transformer for ventilation of core, coil and internal components; minimum 1′-0″ all sides unless noted otherwise.

END OF SECTION


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SURGE PROTECTIVE DEVICES (SPD) - 600 VOLTS AND BELOW

16285-1

SECTION 16285

SURGE PROTECTIVE DEVICES (SPD) - 600 VOLT AND BELOW



This section includes the requirements for the provision of Surge Protective Devices (SPD) equipment having electrical characteristics, ratings and modifications as shown on the contract drawings and specified herein.


A. The SPD units and all components shall be designed, manufactured, tested and installed in accordance with the latest applicable standards of the following:

1. ANSI/IEEE C62.41 and C62.45. 2. ANSI/IEEE C62.1 and C62.11. 3. National Electrical Manufacturers Association (NEMA LS1 Guidelines). 4. National Fire Protection Association (NFPA 70 [NEC], 75, and 78). 5. Underwriters Laboratories (UL 1449, UL 1283 and UL 845). 6. Underwriters Laboratories (UL 489 and UL 198).

B. The unit shall be UL 1449 Listed and CUL Approved as a Surge Protective Device and UL 1283 Listed as an Electromagnetic Interference Filter.

C. The UL 1449 suppression voltage ratings (SVR) shall be permanently affixed to the SPD unit.


The manufacturer of this equipment shall have produced similar electrical equipment for a minimum period of 5 years. A list of installations with similar equipment shall be provided demonstrating compliance with this requirement.

1.4 SUBMITTALS

A. Submit the following information for review/approval in accordance with Section 01330:

1. Descriptive bulletins. 2. Product sheets. 3. Verification that the SPD device complies with the required UL 1449 and UL 1283 suppression voltage ratings (SVR). 4. Actual let-through voltage test data for both the ANSI/IEEE C62.41 Category C3 (combina-tion wave) and B3 (ringwave) tested in accordance with ANSI/IEEE C62.45. 5. UL 1449 Listing/Clamp Voltages. Manufacturer shall provide data showing UL 1449 product listing. Manufacturer shall also submit certified documentation of applicable Location Category Testing in full compliance with NEMA LS 1, paragraphs 2.2.10 and 3.10. 6. Single Pulse Surge Current Capacity Testing. Certified documentation of the unit’s NEMA LS-1 Single Pulse Surge Current Capacity Testing shall be included in the submittal.


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16285-2

7. Minimum Repetitive Surge Current Capacity Testing. Certified documentation of the unit’s ANSI/IEEE C62.41 and ANSI/IEEE C62.45 Minimum Repetitive Surge Current Capacity Testing shall be included in the submittal. 8. Electrical/mechanical drawings showing unit dimensions, weights, installation instruction details, and wiring configuration. 9. Test report from a recognized independent testing laboratory verifying the suppressor components can survive published surge current rating on a per mode and per phase basis using the IEEE C62.41, 8 x 20 microsecond current wave.

B. Submit the following information for record purposes at closeout:

1. O&M Manual. The manufacturer shall furnish with the submittal and with each unit delivered an equipment manual that details the installation, operation, recommended renewal parts list, and maintenance instructions for the specified unit. 2. Drawings. Electrical and mechanical drawings shall be provided by the manufacturer with the submittal and with each unit delivered that show unit dimensions, weights, mounting provisions, connection details and layout diagram of the unit. Include as-built information. Provide drawings with equipment manual.

1.5 EXTENDED WARRANTY

The manufacturer shall provide a full 5-year warranty, which shall initiate after the Owner has accepted the testing results and taken possession of the equipment, against any SPD part failure when installed in compliance with manufacturer’s written instructions and applicable national and local electric codes.


2.1 MANUFACTURERS

A. Square D.

2.2 SURGE PROTECTIVE DEVICES - GENERAL

A. Surge Protective Devices (SPD) equipment shall meet all ratings and features specified herein.

B. Electrical Requirements.

1. Unit Operating Voltage. Refer to drawings for operating voltage and unit configuration. 2. Maximum Continuous Operating Voltage (MCOV). The MCOV shall be greater than 115% of the nominal system operating voltage. 3. Operating Frequency. Range shall be 47 to 63 hertz. 4. Protection Modes. For a wye configured system, the device shall have directly connected suppression elements between line-neutral (L-N), line-ground (L-G), and neutral-ground (N-G). For a delta configured system, the device shall have suppression elements between line to line (L-L) and line to ground (L-G). 5. UL 1449 2nd Edition SVR. The maximum UL 1449 2nd Edition suppression voltage ratings (SVR) for the device shall not exceed the following:

Models 208Y/120 480Y/277

L-N, L-G, N-G 400V 800V


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16285-3

L-L, L-G 800V 1500V

6. ANSI/IEEE Cat C3 Let-Through Voltage. The let-through voltage based on IEEE C62.41 and C62.45 recommended procedures for Category C3 surges (20 kV, 10 kA) shall be less than:

Models 208Y/120 480Y/277

L-N 533V 963V

7. ANSI/IEEE Cat. B3 Let-Through Voltage. Let-through voltage based on IEEE C62.41 and C62.45 recommended procedures for the ANSI/IEEE Cat. B3/C1 ringwave (6 kV, 5000 amps) shall be less than:

Models 208Y/120 480Y/277

L-N 437V 843V

8. Surge Current Capacity. Total surge current per phase (based on an 8x20 microsecond waveform) that the device is capable of surviving shall not be less than value listed below for each piece of equipment.

SPD Exposure Surge Current Capacity per Phase

High

Medium

Low

300 KA

200 KA

160 KA

9. Withstand. Each unit must be capable of surviving the following without failure degradation (>10%):

a. Motor Control Centers and Distribution Panelboards. 20,000 ANSI/IEEE C62.41 Category C3 (20 kV, 10 kA). b. Branch Circuit Panelboards. 5,000 ANSI/IEEE C62.41 Cat. C3 (20 kV, 10 kA).

10. Let-through voltage results shall be measured at the service entrance lugs.

C. SPD Design.

1. High Performance Suppression System. Include an engineered solid-state high performance suppression system metal oxide varistors. The suppression system shall not incorporate components which may degrade performance or long-term reliability of the suppression system. Suppression system shall reduce transient levels and provide protection for sensitive electronics susceptible to catastrophic or long-term damage. 2. Electrical Noise Filter. Include a high-performance EMI/RFI noise rejection filter. Noise attenuation for electric line noise shall be greater than or equal to 44 dB at 100 kHz using the MIL-STD-220A insertion loss test method. The unit shall be complementary listed to UL 1283. 3. Internal Connections. No plug-in component modules or printed circuit boards shall be used as surge current conductors. All internal components shall be hardwired with connections utilizing low impedance copper conductors and compression fittings. 4. Remote Status Monitor. The SPD device shall include form C dry contacts (one NO and one NC) for remote annunciation of unit status. The remote alarm shall change state upon detection of a fault condition.


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16285-4

5. Thermal Protection. Each suppression MOV shall be provided with thermal detection circuit to protect from overheating due to thermal runaway. 6. Diagnostics. Provide unit with following diagnostic features:

a. Audible alarm with silence, reset and test feature. b. Indicator lights per phase. c. System fault indicator (service indicator). d. Surge counter.

7. Disconnecting Means. Provide circuit breaker or disconnect for servicing of SPD unit.

2.3 FACTORY TESTING

Each unit shall be thoroughly factory tested before shipment. Testing of each unit shall include but shall not be limited to UL manufacturing and production-line tests, quality assurance checks, MCOV and clamping voltage verification tests. All tests shall be in accordance with the latest version of NEMA and UL standards.


3.1 INSTALLATION

A. All SPD’s shall be integrally installed inside the motor control centers and panelboards at the manufacturer’s factory.

B. Panelboard and motor control center installed units shall be circuit breaker protected.

C. Provide SPD’s on motor control centers and distribution panelboards as indicated on one-line diagrams. Provide SPD’s on branch circuit panelboards as indicated on panel schedules.

END OF SECTION


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ENCLOSED SAFETY SWITCHES 16410-1

SECTION 16410

ENCLOSED SAFETY SWITCHES



This section includes the requirements for the provision and installation of enclosed safety switches.


A. ANSI/UL 98 - Enclosed and Dead-Front Switches.

B. NEMA KS 1 - Enclosed and Miscellaneous Distribution Equipment Switches.

1.3 SUBMITTALS

Provide product data on each type and rating of switch.


2.1 MANUFACTURER

A. Square D.

2.2 CHARACTERISTICS

A. Voltage. Provide switches with a voltage rating of 250 volts d-c, 240 volts or 600 volts a-c, as required for the installed system voltage.

B. Type. Provide switches conforming to NEMA KS 1 standard for Type HD (heavy duty).

C. Contacts. Provide switches with quick-make, quick-break contacts.

D. Poles. Unless otherwise shown, provide 3-pole, visible blade switches.

2.3 CONSTRUCTION

A. Enclosure. Provide NEMA 4X switch enclosures for indoor and outdoor locations unless otherwise shown.

B. Operating Handle. Provide a handle suitable for padlocking in the OFF position with as many as three padlocks of 5/16-inch diameter shank. Use a defeatable, front accessible, coin-proof door interlock to prevent opening the door when the switch is in the ON position and to prevent turning the switch ON when the door is open.

C. Terminal Shield. Provide incoming line terminals with an insulated shield so that no live parts are exposed when the door is open.


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ENCLOSED SAFETY SWITCHES 16410-2

D. Neutral. Provide each switch with an isolated, fully rated neutral block. Make provisions for bonding the block to the enclosure.

E. Ground. Provide each switch with a ground lug.

F. Fuse Holders. Where fusible switches are shown, provide switches with rejection-type fuse holders which are suitable for use with fuses specified under Section 16490, Fuses - 600 Volt and Below.

G. Nameplates. Provide metal nameplates, front cover mounted, that indicates the switch type, catalog number and horsepower rating (with both standard and time delay fuses).

2.4 LISTING

UL 98 - Safety Standard for Enclosed Switches.


3.1 INSTALLATION

Install switches where indicated on drawings. In general, mount so that operating handle is approximately 60 inches above finished floor. Where grouped, align tops of switches.

END OF SECTION


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AUTOMATIC TRANSFER SWITCHES

16415-1

SECTION 16415



1.1 SUMMARY

Provide automatic transfer switches.


A. ANSI/UL 1008 - Automatic Transfer Switches.

B. NEMA ICS 1-109 - Tests.

C. NEMA ICS 2-447 - AC Automatic Transfer Switches.

D. NFPA 70 - National Electrical Code.

E. NFPA 99 - Essential Electrical Systems for Health Care Facilities.

F. NFPA 110 - Emergency and Standby Power Systems.

G. IEEE 241 - Recommended Practice for Electrical Power Systems in Commercial Buildings.

H. IEEE 446 - Recommended Practice for Emergency and Standby Power Systems.

1.3 SUBMITTALS

Include the following information in submittal:

A. Rated current, voltage and frequency.

B. Number of poles.

C. UL 1008 3-cycle close and withstand rating.

D. Physical dimensions.

E. NEMA enclosure type.

F. Itemized list of accessories.

G. Schematic diagram (show wiring and only those components which are part of switch).

H. Show all factory wiring on wiring diagram and clearly indicate all wiring and connections to remote devices which are to be made in the field. (Show only that wiring which pertains to switch and remote devices.)


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16415-2


2.1 MANUFACTURERS

Acceptable manufacturer is Cummins Power Generation.

2.2 TYPE

Provide a switch which is transition, electrically operated and mechanically held in each direction, and which is true double-throw with no intermediate position. Provide UL listing 1008, Automatic Transfer Switches. Rating shall be as indicated on the drawings.

2.3 OPERATION

A. General. Provide automatic transfer switches (ATS) with number of poles, voltage and current ratings as shown on the plans. Each ATS shall consist of an inherently double-throw power transfer switch unit and a control module interconnected to provide complete automatic operation.

B. Construction.

1. The transfer switch unit shall be electrically operated and mechanically held. The electrical operator shall be either a single or dual motor design with over-center type linkage solenoid mechanism, momentarily energized to minimize power consumption and heat generation. The switch shall be positively locked and unaffected by voltage variations or momentary outages so that contact pressure is maintained at a constant value and temperature rise at the contacts is minimized for maximum reliability and operating life. The switch shall be mechanically interlocked to ensure only one of two possible positions - normal or emergency - for single solenoid design and three possible positions - normal, off, emergency - for dual motor design. 2. All main contacts shall be silver-plated copper composition. All switches shall have segmented, blow-on construction for high withstand current capability and be protected by separate arcing contacts. 3. ATS utilizing components of molded-case circuit breakers, contactors or parts thereof which have not been intended for continuous duty, repetitive switching or transfer between two active power sources are not acceptable. 4. Utilize quick-make quick-break contacts mounted so that contact position may be verified by observation.

C. Operation.

1. The voltage of each phase of the normal source shall be monitored, with pickup adjustable from 85 to 100 percent and dropout adjustable from 75 to 98 percent of pickup setting, both in increments of 1 percent, and shall be fully field adjustable. Repetitive accuracy of settings shall be + 2 percent or better over an operating temperature range of -20°C to 70°C. Factory set to pick up at 90 percent and drop out at 85 percent. 2. Provide single-phase voltage sensing of the emergency source, with a pickup adjustable from 85 to 100 percent (and dropout fixed at 84 to 86 percent of pickup), and frequency sensing with pickup adjustable from 90 to 100 percent (and dropout fixed at 87 to 89 percent of pickup). Both pickup settings shall be fully field adjustable. Repetitive accuracy of settings shall be + 2 percent or better over an operating temperature range of -20°C to 70°C. Factory set to pick up at 90 percent voltage and 95 percent frequency.


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16415-3

3. The control module shall include four time delays that are fully field adjustable in increments of at least 13 steps over the entire range as follows:

a. Time delay to override momentary normal source outages to delay all transfer switch and engine starting signals. Adjustable from 0 to 6 seconds. Factory set at 1 second. b. Transfer to emergency time delay. Adjustable from 0 to 5 minutes. Factory set at 0 minutes, unless indicated otherwise on the plans. c. Retransfer to normal time delay. Time delay is automatically bypassed if emergency source fails and normal source is acceptable. Adjustable from 0 to 30 minutes. Factory set at 30 minutes. d. Unloaded running time delay for emergency engine generatr cooldown. Adjustable from 0 to 60 minutes. Factory set at 5 minutes.

4. Provide a set of DPDT gold-flashed contacts rated 10 amps, 32 VDC for a low-voltage engine start signal when the normal source fails. The start signal shall prevent dry cranking of the generator by requiring the generator to reach proper output, and to run for the duration of the cooldown setting, regardless of whether the normal source restores before the load is transferred. 5. Provide a pushbutton to bypass time delay on retransfer to normal. 6. Provide a momentary-type test switch to simulate a normal source failure. 7. Provide output terminals to signal the actual availability of the normal and emergency sources, as determined by the voltage-sensing pickup and dropout settings for each source. 8. Provide four sets of auxiliary contacts rated 10 amps, 480 VAC, consisting of four contacts closed when the ATS is connected to normal and four contacts closed when the ATS is connected to emergency. Also, provide four sets of signal lights to indicate when the ATS is connected to normal source, when the ATS is connected to emergency source, when normal power is available, and when emergency power is available. Form C contacts are unacceptable. Contacts shall be wired to an accessible terminal strip. 9. Each switch shall be furnished with an operator’s manual providing installation and operating instructions. 10. On all switches not part of a bypass isolation switch assembly, provide an external emergency manual operator, UL listed for transferring the switch to either source under load.

D. Inphase Monitor. If the ATS is of a single solenoid design, an inphase monitor shall be built-in to the ATS and shall control transfer so that motor load inrush currents do not exceed normal starting currents, to avoid nuisance tripping of circuit breakers and possible mechanical damage to motor couplings. The inphase monitor shall operate without external control of electrical loads and without any external control of the power sources. The monitor shall compare the phase relationship and frequency difference between the normal and emergency sources and permit transfer the first time the sources are within 15 electrical degrees and only if transfer can be accomplished within 60 electrical degrees as determined by monitoring the frequency difference. Inphase transfer shall be accomplished if both sources are within 2 Hz of nominal frequency and 70 percent or more of nominal voltage. This is not required for dual motor design.

E. Center Off Position. If the ATS is of the dual motor design, a time delay relay shall be provided to vary the center off delay from 0 to 60 seconds.

2.4 MAIN CONTACT PROTECTION AND WITHSTAND CURRENT RATINGS

A. Protect main contacts by providing arc barriers on each contact, and on switches rated above 300 amperes by providing separate arcing contacts.

B. The ATS shall be UL 1008 listed for a 3-cycle close and withstand current rating of 42,000 amperes minimum. If the drawings indicate a higher available fault current, provide the higher rating. Series rating of switches with particular circuit breakers or fuses is not acceptable.


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16415-4

2.5 NEUTRAL BAR

Provide a neutral bar with the same capacity as the ampere rating of the switch.

2.6 ACCESSIBILITY

Provide an ATS where parts and components may be inspected or replaced from the front of the switch without major disassembly, disconnection of power conductors, or removal of the switch from the enclosure.

2.7 ENCLOSURE

Provide NEMA 12 switch enclosure suitable for wall or floor mounting in indoor locations. Provide a NEMA 4X switch enclosure for outdoor locations.

2.8 PRODUCT DATA

Permanently attach wiring diagrams and maintenance instructions on the inside of enclosure door in a mounting designed to hold the data.


3.1 INSTALLATION

Install the transfer switch as shown on the drawings. Make the installation in accordance with manufacturer’s instructions.

3.2 PAINTING

Restore any marred surfaces to factory finish.

3.3 TESTING

Test the switch with the packaged electric generator set in operating condition. Demonstrate to the Owner’s representative that the automatic transfer switch performs all required functions.

END OF SECTION


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MOTOR STARTERS 16425-1

SECTION 16425

MOTOR STARTERS - 600 VOLT AND BELOW



This section includes the requirements for the provision and installation of individual motor starters rated 600 volts and below.


A. Reference Standards.

1. NEMA ICS - Industrial Controls and Systems. 2. NFPA 70 - National Electrical Code (NEC). 3. UL 508 - Industrial Control Equipment.

B. Qualifications. The manufacturer of this equipment shall have produced similar electrical equipment for a minimum period of 5 years. When requested, an acceptable list of installations with similar equipment shall be provided demonstrating compliance with this requirement.

1.3 SUBMITTALS

Provide product data, including the following:

A. Ratings including:

1. Voltage. 2. Horsepower and/or continuous current.

B. Dimensioned outline drawings.

C. Conduit entry/exit locations.

D. Cable terminal sizes.

E. Wiring diagrams.

1.4 SPARES

Provide the greater of 10 percent or three spare fuses for each size and type fuse used in the installed equipment.


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2.1 MANUFACTURERS

A. Square D.

2.2 MAGNETIC MOTOR STARTER

A. Type. Provide magnetic, full-voltage, nonreversing, across-the-line motor starters unless otherwise indicated. Where reversing starters are shown, provide factory assembled and wired unit with interlocked forward and reverse contactors. Include electrical interlock and integral time delay transition between FORWARD and REVERSE rotation. Starters shall be electrically and mechanically interlocked to prohibit both starters from being energized simultaneously.

B. Overload Relay - Bimetallic. Provide in each phase leg an ambient compensated, bimetallic type thermal overload relay (TOL) with interchangeable thermal units.

C. Contactor. Size contactors according to NEMA standards or as shown. Provide main pole in each phase leg, the number and type of auxiliary contacts to perform the required functions, and two spare auxiliary contacts, one normally open and one normally closed. Use double break contacts of silver-cadmium oxide or similar material to minimize sticking or welding. Provide contactor coils suitable for continuous operation at 120 volts, 60 hertz.

D. Control Power Transformer.

1. Voltage. Provide in each enclosure a single-phase control power transformer with a 480-volt primary and a 120-volt secondary. 2. Fuses. Fuse both primary lines of the transformer and connect to Line 1 and Line 2. Fuse the secondary line leaving transformer terminal X1. Ground the line leaving terminal X2. Use rejection-type fuse clips and RK-1 type current limiting fuses on the primaries. Coordinate primary fuses with secondary fuse to clear a faulted transformer but not blow on magnetizing inrush current. 3. Size. Provide manufacturer’s standard size transformer unless noted otherwise on the drawings.

E. Enclosure. Provide NEMA 4X enclosures, unless otherwise indicated on drawings.

2.3 COMBINATION CIRCUIT BREAKER-STARTER

A. Type. Provide combination circuit breaker and magnetic motor starter as indicated on the drawings.

B. Thermal-Magnetic Circuit Breaker. Where indicated on drawings, provide circuit breaker which is quick-make and quick-break on both manual and automatic operation. Provide a trip-free breaker which is trip indicating. Incorporate inverse time characteristic by bimetallic overload elements and instantaneous characteristic by magnetic trip. For 2-pole and 3-pole breakers, provide the common-trip type so that an overload or fault on one pole will trip all poles simultaneously.

C. Operators. Provide switch operators mounted through the panel door and permitting operation of the switch with the door closed. Operators shall be capable of being padlocked in the OPEN or OFF position with as many as three padlocks of 5/16-inch diameter shank. Use a defeatable, front-accessible,


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coin-proof, mechanical, door interlock to prevent opening the door when the operator is in the CLOSED or ON position, and to prevent placing the operator in the CLOSED or ON position when the door is open.

D. Starter. Provide magnetic motor starter as specified in paragraph 2.2.

E. Control Devices. Control devices are furnished with vendor furnished control panels in other specification sections unless indicated otherwise. As a minimum provide control power transformer and motor space heater control functions.

2.4 CONTROL DEVICES

Provide the following control devices for each starter as required to meet the criteria defined in appropriate sections of Division 11.

A. Selector Switches. Heavy-duty, oil-tight, maintained contact, 3-position, with marked nameplate HAND-OFF-AUTOMATIC, unless otherwise indicated.

B. Pushbuttons. Heavy-duty, oil-tight, momentary contact with marked nameplate START-STOP, unless otherwise indicated.

C. Indicating Lights. Pilot light assemblies shall be heavy-duty, oil-tight, push-to-test, transformer-type, long-life, high-density light-emitting diode (LED) type. Incandescent or neon lamps are not acceptable. Provide red (running) and green (stopped) LED lamps with clear or matching color lenses. On two-speed starters, provide amber (low speed), red (high speed) and green (stopped) lenses.

D. Instrumentation Control Interface Equipment. The Contractor shall furnish and install all necessary equipment and devices including but not limited to control contacts, switches, terminal boards, conduit and control wiring for the proper operation of the equipment. The Contractor shall verify with the equipment manufacturer all required equipment and devices for the operation of the Starter. The Contractor shall furnish and install all equipment and devices as shown on the Instrumentation Drawings required for the control and monitoring of the equipment. 2.5 SOLID-STATE REDUCED-VOLTAGE MOTOR STARTER

A. Type.

1. Where indicated on drawings, provide solid-state reduced-voltage bypass motor starter, Square D Altivar or approved substitution. 2. The solid-state reduced-voltage starter shall be UL and CUL listed and consist of an SCR-based power section, logic board and paralleling bypass contactor.

3. Power Section.

a. The SCR-based power section shall consist of six back-to-back SCRs and shall be rated for a minimum peak inverse voltage rating of 1500 volts PIV. b. Units using triacs or SCR/diode combinations shall not be acceptable. c. Resistor/capacitor snubber networks shall be used to prevent false firing of SCRs caused by dv/dt effects.

4. Logic Board.


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a. The logic board shall be mounted for ease of testing, service and replacement. It shall have quick-disconnect plug-in connectors for current transformer inputs, line and load voltage inputs and SCR gate firing output circuits. b. The logic board shall be identical through all ampere ratings and voltage classes and shall be conformably coated to protect environmental concerns.

B. Power Module Overload and Fault Protection.

1. The power module shall provide electronic overload protection based on an inverse time-current algorithm.

a. Overload protection shall be adjusted via the logic board. b. Provide selectable Class 10 or 20 overload characteristic. c. Units using bi-metallic thermal overload relays are not acceptable.

2. Over-temperature protection (on heat sink) shall be standard. 3. The solid-state logic shall be phase sensitive and shall inhibit starting on incorrect rotation. Improper phase rotation shall be indicated on the starter logic board. 4. Starters shall protect against a phase loss/unbalance condition, shutting down if a 35 percent current differential between any two phases is encountered. 5. Provide a normally open (NO) contact to annunciate fault conditions, with contact ratings suitable for the alarm/annunciator circuit. Provide an LED display on the logic board to indicate type of fault (current trip, phase loss, phase rotation).

C. Control. 1. Provide the following logic board adjustments:

a. Ramp Time. 1 to 45 seconds, on a hexadecimal switch. b. Initial Torque. 100 to 200 percent current, on a hexadecimal switch. c. Current Limit. 100 to 500 percent current, on a hexadecimal switch. d. Motor Full Load Running Amperage (FLA). 4 to 1 range of starter, on a dip switch.

2. Optional smooth stopping shall provide a linear voltage deceleration, adjustable from 1 to 75 seconds.

D. Bypass Contactor. 1. The paralleling bypass contactor shall energize when the motor reaches full speed and close/open under one times motor current. 2. The contactor shall be fully rated for across-the-line starting duty. 3. The contactor shall utilize an energy balanced contact closure to limit contact bounce and an intelligent coil controller to optimize coil voltage during varying system conditions.

E. Disconnect, Overcurrent, Interrupting and Withstand Ratings.

1. Provide enclosed units with a thermal magnetic circuit breaker or motor circuit protector (MCP) for short-circuit protection and quick-disconnect means. 2. Motor starters and circuit breakers/motor circuit protectors shall be rated per UL 508D for a withstand rating of 65 kAIC RMS. 3. Maximum continuous operation shall be at 115 percent of continuous ampere rating. 4. Circuit breakers/motor circuit protectors (MCPs) shall be Cutler-Hammer type HMCP or approved substitution.

F. Manufacturers.


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1. Square D Company. 2. The manufacturer of the solid-state starter shall employ a field-based factory service organization for the purpose of start-up and repair of units. Third-party service contractors are not acceptable.


3.1 INSTALLATION

Install units where indicated on the drawings. In general, mount combination units so that operating handle is approximately 44 inches above finished floor. On non-combination units, mount so that control device is approximately 44 inches above finished floor. Where grouped, align tops of units. Provide housekeeping pads for freestanding and floor-mounted units, as specified in Section 16050.

3.2 OVERLOAD SETTINGS

Set overload relays at maximum values permitted by NEC 430-32, based on actual installed motor nameplate full load amperes. Coordinate overload settings with NEC 460-9 requirements where power factor correction capacitors are provided.


A. Provide the services of a qualified factory-trained manufacturer’s representative to assist in installation and start-up of the equipment specified under this section. The manufacturer’s representative shall provide technical direction and assistance in general assembly of the equipment, connections and adjustments, and testing of the assembly and components contained herein.

B. The following minimum work shall be performed under the technical direction of the manufacturer’s service representative.

1. Inspection and final adjustments. 2. Operational and functional checks of controllers/starters and spare parts.

C. Provide copies of the manufacturer’s field start-up report to the Engineer.

END OF SECTION


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MOTOR CONTROL CENTERS 16445-1

SECTION 16445

MOTOR CONTROL CENTERS



This section includes the requirements for the provision of motor control centers for use on 3-phase power systems rated 600 volts and below, and which conform to NEMA Type 1B-D wiring, Type NEMA 3R construction.


A. Reference Standards. Design, test, assemble and install in conformance to the latest edition of the following applicable industry standards, where applicable.

1. ANSI C19 - Industrial Control Apparatus. 2. ANSI/NEMA ICS1 - General Standards for Industrial Control and Systems. 3. ANSI/NEMA ICS2 - Industrial Control Devices, Controllers and Assemblies. 4. ANSI/NEMA ICS4 - Terminal Blocks for Industrial Use. 5. ANSI/NEMA ICS6 - Enclosures for Industrial Controls and Systems. 6. NEMA AB1 - Molded Case Circuit Breakers. 7. NEMA PB1.1 - Instructions for Safe Installation, Operation and Maintenance of Panelboards Rated 600 Volts or Less. 8. NEMA PB1.2 - Application Guide for Ground Fault Protective Devices for Equipment. 9. NFPA 70 - National Electrical Code (NEC). 10. UL 467 - Standard for Safety, Grounding and Bonding Equipment. 11. UL 489 - Standard for Safety, Molded-Case Circuit Breakers and Circuit-Breaker Enclosures. 12. UL 506 - Standard for Safety, Specialty Transformers. 13. UL 508 - Industrial Control Equipment. 14. UL 845 - Electric Motor Control Centers.

B. Qualifications. The manufacturer of this equipment shall have produced similar electrical equipment for a minimum period of 5 years. When requested, an acceptable list of installations with similar equipment shall be provided demonstrating compliance with this requirement.

1.3 SUBMITTALS

A. Provide product data, including the following:

1. Ratings, including voltage and horsepower or continuous current. 2. Cable terminal sizes. 3. Short circuit current ratings.

B. Dimensional Drawings. Submit dimensional drawings of the motor control center, including top and bottom views showing entry and exit space for conduits and busways, front and side elevations showing arrangement of all devices, and busway connection details. Also include dimensional data on all buses including material type and capacity of the buses.


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C. Wiring Diagrams. Power, signal, and control wiring for class and type of motor control center. Provide schematic wiring diagram for each type of controller.

D. Electrical Information. Submit one line diagrams for equipment being provided. Also submit information on all protective devices including type, ratings, and settings of all trips provided, to include ground fault relay settings.

E. Coordination Curves. Manufacturer shall provide coordination curves on log-log paper for the main protective device and for the largest branch circuit devices. These curves shall also show the ground fault protective relay.


2.1 MANUFACTURER

A. Square D.

2.2 DESCRIPTION

A. General. Provide a completely factory assembled motor control center from incoming line lugs to load terminals of all branch protective devices. Include all necessary buses, supports, devices and provisions for future connections as shown on the one-line diagrams and as specified.

B. Size. The physical size and configuration of the motor control center and equipment may be varied to suit the manufacturer’s standard design, provided the intended functions are accomplished. Any change in size or configuration must be so noted on the submittal. Any changes made are restricted by Section 16050.

C. Listing.

1. The motor control center shall be UL listed as suitable for use as service entrance equipment. 2. UL 845 - Electric Motor Control Centers.

2.3 ENCLOSURE

A. Construction.

1. Fabricate the enclosure of one or more rigid, freestanding sheet metal cubicles bolted together to form a rigid assembly. Use not less than No. 14 gauge, cold-rolled steel. Grind smooth any imperfections, such as welding splatter, sharp edges, burrs, etc., before finishing. 2. Make each vertical section nominally 20 inches wide, 20 inches deep and 90 inches high, unless noted otherwise. 3. Provide doors with substantial vertical hinges, permitting them to swing out. Provide a defeatable mechanical interlock that prevents door from being opened when disconnecting means is in closed position. 4. Provide a hinged wireway the full height of each vertical section for component wiring installation. 5. Construct the enclosure according to NEMA 12 requirements for interior locations and NEMA 3R gasketed requirements for exterior locations.. 6. Provide suitable lifting means to facilitate handling of the motor control center.


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B. Component Isolation. Mount each component, such as a fused switch, combination starter, dry-type transformer or branch circuit panel in a separate compartment and effectively isolate from adjacent units, including buses. Make each component readily accessible and removable from the front of the cubicle.

C. Cable Entrance. Make provisions for top and bottom cable entrances.

D. Finish. Grind all interior and exterior steel and aluminum surfaces smooth, with all burrs, sharp edges, welding splatters, loose rust, scale and the like totally removed after fabrication. The finish coat shall consist of ANSI 61 Gray thermosetting polyester powder paint, or acceptable equivalent, applied electrostatically to pre-cleaned and phosphatized steel and aluminum internal and external surfaces with a minimum 1.5 mil DFT. The coating shall have a minimum corrosion resistance of 300 hours to 5 percent salt spray. Prior to shipment, all switchgear exterior surfaces shall be given a topcoat of ANSI 61 Gray high-gloss enamel with a minimum 1.5 mil DFT. Final interior finish shall be flat white (non-gloss) enamel with a minimum 1.5 mil DFT. The use of galvanized metal for interior or exterior surfaces is not acceptable. Provide a minimum of one quart of finish paint for touch-up after field installation.

2.4 BUS STRUCTURE

A. Materials.

1. Bar. Fabricate buses of 98 percent IACS conductivity tin-plated copper. Use full lap construction and make main bus connections using a minimum of two bolts. 2. Cable. Standard, code grade copper, sized according to the NEC. 3. Bracing. Adequate to withstand mechanical forces exerted during a short circuit directly from a source with an available fault current not less than value indicated on drawings.

B. Main Horizontal Bus.

1. Locate at top and rated as indicated on the drawings. 2. Arrange to permit future extensions.

C. Vertical Buses.

1. Rate as required but not less than 300 amperes. 2. Provide stab isolation shutter mechanisms to isolate and insulate vertical bus and stabs from cubicle enclosures.

D. Ground Bus. Provide a continuous tin-plated copper ground bus for entire length of the enclosure. Arrange to permit future extensions. Ground motor control center parts which do not carry current. Terminations must be of an approved pressure connector type.

2.5 CIRCUIT BREAKERS

A. Type. Provide molded case thermal-magnetic circuit breaker which is quick-make and quick-break on both manual and automatic operation. Provide a trip-free breaker which is trip indicating. Incorporate inverse time characteristic by bimetallic overload elements and instantaneous characteristic by adjustable magnetic trip. For 2-pole and 3-pole breakers, provide the common-trip type so that an overload or fault on one pole will trip all poles simultaneously.

B. Operators. Provide breaker operators mounted through the panel door and permitting operation of the breaker with the door closed. Operators shall be capable of being padlocked in the OPEN or OFF


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position with as many as three padlocks of 5/16-inch diameter shank. Use a defeatable, front-accessible, coin-proof, mechanical, door interlock to prevent opening the door when the operator is in the CLOSED or ON position, and to prevent placing the operator in the CLOSED or ON position when the door is open.

C. Ratings. As indicated on drawings.

2.6 STARTERS

Provide starters as specified in Section 16425.

2.7 CONTROL RELAYS

Provide industrial control relays as shown on drawings having 120-volt, 60-hertz coils standard convertible NO or NC 10-ampere, 600-volt contacts and building module feature enabling relay to have up to 12 poles.

2.8 TIMING RELAYS

Provide solid-state time-delay type as shown on drawings, having 120-volt, 60-hertz coils, 10-ampere, 600-volt contacts and an adjustable timing range of approximately 0.3 to 30 seconds, unless noted otherwise on the drawings.

2.9 CONTROL WIRING

A. Wiring. Install and test control and small wiring inside the MCCs at the factory, including control wiring, instrument and relay wiring, secondary leads from instrument transformers, etc. Neatly and carefully install wiring in suitable wiring gutters or conduit, using standard 600-volt switchboard type, stranded copper wire No. 14 AWG or larger. Identify each wire at terminals by means of permanent, sleeve-type wire markers. Secure wiring from hinged doors and panels to enclosure in a manner to allow ample flexibility in bending. Make wiring continuous from terminal to terminal, without splices.

B. Terminals. Terminate wire on instruments, devices, transformers and terminal blocks by means of ring-tongue type connectors under screws, marked in accordance with the manufacturer’s wiring diagram. Locate terminal blocks in readily accessible places.

C. Spare Contacts. Wire spare contacts to suitably identified terminals for external connections and clearly show these connections on shop drawings.

D. Spare Terminals. In addition to specified spare contact terminals, provide six spare terminals on each terminal block provided.

2.10 BRANCH CIRCUIT PANELBOARD

A. Type. In the MCC, provide a UL-listed, circuit-breaker type branch circuit panelboard with tin-plated copper bus that meets the requirements of Section 16442, Panelboards - Distribution and Branch Circuit.

B. Mounting. Flush mount the dead-front assembly inside the MCC. Provide access through the cubicle front by a small door with spring catch. Supply a directory, including frame, with a heat-resistant, transparent face.


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C. Circuit Breakers. Provide circuit breakers which are quick-make and quick-break on both manual and automatic operation. Provide a trip-free breaker which is trip indicating. Incorporate inverse time characteristic by bimetallic overload elements and instantaneous characteristic by magnetic trip. For 2-pole and 3-pole breakers, provide the common-trip type so that an overload or fault on one pole will trip all poles simultaneously. Handle ties are not acceptable.

D. Panelboard Transformer. For the branch circuit panelboard specified above, provide a dry-type transformer conforming to Section 16276, Dry-Type Transformers - 600 Volt and Below Primary and Rated 500 Kva and Smaller, and rated as shown on drawings.

E. SPD. For the branch circuit panelboard specified above. Provide surge protective device conforming to Section 16285, Surge Protective Devices– 600 Volts and Below.

2.11 NAMEPLATES

A. Main Nameplate. Provide MCC with a stainless steel or equal nameplate prominently displayed on the front, indicating manufacturer’s name, address and shop order number, year manufactured, and the following ratings:

1. Nominal voltage rating and frequency. 2. Main bus continuous current rating. 3. Maximum 3-phase rms symmetrical short circuit current rating.

B. Unit Nameplates. Provide each unit with a black-white-black lamacoid nameplate with 3/16-inch-high white lettering secured to front of unit by means of oval-head chrome-plated brass screws, immediately below switch handle. Actual nameplate legend, which may consist of up to three lines, will be provided by the Owner’s representative on shop drawings as approved.

C. Caution Signs. Provide caution signs in accordance with OSHA requirements.

2.12 SPD FOR MCC

For the MCC, provide surge protective device conforming to Section 16285, Surge Protective Devices (SPD) – 600 Volt and Below.


3.1 PREPARATION

Construct a concrete pad in accordance with Section 16050, Electrical General Provisions. Verify dimension of the housekeeping pad and the embedded leveling channels and conduit stub-ups.

3.2 INSTALLATION

A. Install the motor control center in accordance with the manufacturer’s published instructions.

B. Torque bus bar bolts to manufacturer=s recommendations, and tighten nuts and bolts on the steel structure to ensure structural integrity.


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3.3 EQUIPMENT ADJUSTMENT

A. Set overload relays at maximum values permitted by the NEC, based on actual installed motor nameplate full load amperes. Coordinate overload settings with NEC requirements where power factor correction capacitors are provided.

B. Adjust the magnetic setting on motor circuit protectors in accordance with motor inrush currents (nameplate data) and NEC requirements.

C. Touch-up Painting. Restore damaged surfaces to factory finish. Deliver to Owner all leftover paint in suitably labeled, sealed containers.

D. Inspection. Thoroughly inspect motor control center for items such as loose connections and presence of foreign material, and remedy prior to energizing.

3.4 TESTING

A. Demonstrate that motor control circuits function properly, as specified, under all required operating conditions.

B. Where units do not function properly, and where possible, the unit shall be corrected onsite and reinstalled. Where the unit cannot be corrected on site, remove and return to the manufacturer for correction or replacement. This shall not relieve the Contractor of the responsibility to complete the installation within the schedule, as stipulated in the contract documents.

C. Retest corrected units to demonstrate proper operation per paragraph 3.6A above.

END OF SECTION


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FUSES – 600 VOLT AND BELOW 16490-1

SECTION 16490

FUSES – 600 VOLT AND BELOW



This section specifies the furnishing and installation of low voltage fuses rated 600 volts and below, 6000 amperes and below.


A. ANSI/NEMA FU 1 - Low Voltage Cartridge Fuses.

B. ANSI/UL 198C - High-Interrupting-Capacity Fuses, Current-Limiting Type.

C. ANSI/UL 198D - Class K Fuses.

D. ANSI/UL 198E - Class R Fuses.

1.3 SUBMITTALS

Provide product data on fuses.

1.4 SPARE FUSES

As spares, provide the greater amount of either three fuses or 10 percent of each size and type installed. Deliver the spare fuses to the Owner at the time of final acceptance of the project. Neatly encase the spare fuses in suitable containers or cabinets.



A. Low voltage fuses shall be products of a single manufacturer.

B. Acceptable manufacturers are Bussman, Gould (Shawmut) and Littelfuse.

2.2 VOLTAGE

Provide fuses with a voltage rating suitable for the nominal voltage of the system in which they are to be applied.

2.3 TYPES

A. Time Delay Fuses. Unless otherwise indicated, provide UL Class RK-5 time delay, current limiting fuses having 200,000 rms symmetrical amperes interrupting rating. Use on all 600-ampere or smaller circuits supplying individual motors and transformers, and where otherwise indicated.


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FUSES – 600 VOLT AND BELOW 16490-2

B. Non-Time Delay Fuses. Fuses indicated by "K-1" on the drawings are UL Class RK-1 non-time delay having 200,000 rms symmetrical amperes interrupting rating. Use on all 600-ampere or smaller circuits supplying branch circuit panelboards, resistance heating and where otherwise indicated.

C. Class L Fuses. Fuses rated 601-6000 amperes are UL Class L with 200,000 rms symmetrical amperes interrupting rating.


3.1 INSTALLATION

A. Instructions. Follow the manufacturer's installation instructions.

B. Fuse Clips. Check fasteners on fuse clips for tightness when installing fuses.

C. Labels. Install fuses so label is in an upright, readable position. Fuses without labels are not acceptable.

END OF SECTION


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LIGHTING FIXTURES AND LAMPS

16510-1

SECTION 16510




This section includes the requirements for the provision of lighting fixtures, complete with lamps and other accessories.


A. ANSI C78 Series - Lamps.

B. ANSI C82 Series - Ballasts.

C. ANSI/UL 844 - Electric Lighting Fixtures for Use in Hazardous (Classified) Locations.

D. ANSI/UL 935 - Fluorescent-Lamp Ballasts.

E. ANSI/UL 1029 - High-Intensity-Discharge Lamp Ballasts.

F. ANSI/UL 1570 - Fluorescent Lighting Fixtures.

G. ANSI/UL 1571 - Incandescent Lighting Fixtures.

H. ANSI/UL 1572 - High-Intensity-Discharge Lighting Fixtures.

I. NFPA 70 - National Electrical Code (NEC).

1.3 SUBMITTALS

Provide product data on each lighting fixture, type of lamp and poles.


2.1 LIGHTING FIXTURES

A. General. Lighting fixtures are specified by type and manufacturer on the drawings.

A. LED LUMINAIRES

1. Product Requirements

a. LED luminaire shall consist of an assembly that utilizes LEDs as the light source. In addition, a complete luminaire shall consist of a housing, LED array, and electronic driver (power supply).

b. LED luminaire shall be rated for a minimum operational life of 50,000 hours as defined


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16510-2

by IES LM-80 and TM-15. Conducted at 40°C ambient temperature.

c. LED luminaire shall be designed to operate at an average operating temperature of 35°C.

d. The operating temperature range shall be -30°C to +40°C.

e. Some parameters and tests (such as IESNA standard LM-80-08) shall be conducted at different ambient temperatures.

f. LED luminaire shall meet all parameters of this specification throughout the minimum operational life when operated at the average operating temperature.

g. The individual LEDs shall be connected such that a catastrophic loss or the failure of one LED will not result in the loss of the entire luminaire.

h. Luminaire shall be constructed such that LED modules may be replaced or repaired without replacement of whole luminaire.

2. Electrical Requirements

a. Operation Voltage:

1) The luminaire shall operate from a 60 HZ ±3 HZ AC line over a voltage ranging from 110 VAC to 300 VAC. The fluctuations of line voltage shall have no visible effect on the luminous output.

b. Power Factor: The luminaire shall have a power factor of 0.90% or greater over the voltage range specified above.

c. THD: Total harmonic distortion (current and voltage) induced into an AC power line by a luminaire shall not exceed 20 percent over the voltage range specified above.

d. Surge Suppression: The luminaire on-board circuitry shall include fused surge protection devices (SPD) to withstand high repetition noise transients as a result of utility line switching, nearby lightning strikes, and other interference.

1) The SPD shall protect the luminaire from damage and failure for common mode transient peak voltages up to 10 kV (minimum) and transient peak currents up to 5 kA (minimum). SPD shall conform to UL 1449 depending on the components used in the design.

2) SPD performance shall be tested per the procedures in ANSI/IEEE C62.41-1992 (or current edition) for Category C (standard).

3) The SPD shall fail in such a way as the luminaire will no longer operate.

4) The SPD shall be field replaceable.

e. Operational Performance: The LED circuitry shall prevent perceptible flicker to the unaided eye over the voltage range specified above.


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f. RF Interference: The luminaire and associated on-board circuitry must meet Class A emission limits referred in Federal Communications Commission (FCC) Title 47, Subpart B, Section 15 regulations concerning the emission of electronic noise.

g. Dimming: The luminaire shall be capable of step dimming without perceivable flicker over a range of 100%, 50%, and 30% of rated lumen output, or as indicated on contract documents. Dimming shall be controlled by a 0-10V signal, or as indicated on contract documents.

3. Photometric Requirements

a. Optical Assemblies: LEDs shall be provided with discreet over optical elements to provide IESNA Type II, III, IV or V distributions. Additional distributions for spill light control shall be utilized when light trespass must be mitigated. Mitigation must take place without external shielding elements. Optical assemblies shall have a minimum efficiency of 85% regardless of distribution type. For Type II and Type III distributions street side efficiencies shall be a minimum of 80%. All LEDs and optical assemblies shall be mounted parallel to the ground. All LEDs shall provide the same optical pattern such that catastrophic failures of individual LEDs will not constitute a loss in the distribution pattern.

b. Backlight – Uplight – Glare (BUG rating):The luminaire shall not allow more than 10 percent of the ratedIESNA TM-15.

c. Light Output

1) The lumen output shall not decrease by more than 30% over the minimum operational life of 50,000 hours (L70).

2) The measurements shall be calibrated to standard photopic calibrations.

4. Light Color/Quality

a. Corrected Color temperature (CCT) range between 2,700K and 5,000K shall be correlated to chromaticity as defined by the absolute (X,Y) coordinates on the 2-D CIE chromaticity chart.

b. The color rendition index (CRI) shall be 65 or greater.

5. Physical and Mechanical Requirements

a. The luminaire shall be a single, self-contained device, not requiring on-site assembly for installation. The power supply for the luminaire shall be integral to the unit.

b. The assembly and manufacturing process for the SSL luminaire shall be designed to assure all internal components are adequately supported to withstand mechanical shock and vibration.

c. The electronics/power supply enclosure shall be internal to the SSL luminaire and be accessible per UL requirements and meet wet location requirements per NEMA/UL.

d. The optical assembly of the luminaire shall be protected against dust and moisture intrusion per the requirements of IP-66 (minimum).


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6. Door shall be hinged and secured to the housing in a manner to prevent its accidental opening and falling to the ground.


3.1 COORDINATION

Install lighting fixtures in accordance with manufacturer’s written instructions, NEC and NECA. Before placing order, verify that the lighting fixtures are compatible with the specified ceiling systems as indicated on the drawings. Regardless of the catalog number prefixes and suffixes shown, furnish fixtures with the proper trim, frame, support, hangers, ballasts, voltage rating, and other miscellaneous appurtenances to properly coordinate with building conditions. If a fixture type designation is omitted, furnish fixture of the same type as shown for rooms of similar usage. Confirm with Engineer.

3.2 INSTALLATION

A. Fixtures must be completely wired and lamps installed. Lighting fixtures must be operating properly at final completion.

END OF SECTION


WATER PLANTS


16510-5
