SECTION 01410
SPECIAL INSPECTIONS AND STRUCTURAL TESTING
PART 1 – GENERAL
1.1 GENERAL REQUIREMENTS:
1.1.1 Special Inspections and Structural Testing shall be in accordance with Chapter 17 of the 2015 International Building Code as amended by New York State (IBCNYS).
1.1.2 The program of Special Inspection and Structural Testing is a Quality Assurance program intended to ensure that the work is performed in accordance with the Contract Documents.
1.1.3 This Specification Section is intended to inform the Contractor of the Owner’s quality assurance program and the extent of the Contractor’s responsibilities. This Specification Section is also intended to notify the Special Inspector, Testing Laboratory, and other Agents of the Special Inspector of their requirements and responsibilities.
1.2 SCHEDULE OF INSPECTIONS AND TESTS:
1.2.1 Required inspections and tests are described in the Statement of Special Inspections provided at the end of this Section, and in the individual specification sections for the items to be inspected or tested.
1.3 QUALIFICATIONS:
1.3.1 The Special Inspector shall be a licensed Professional Engineer, Structural Engineer or as specified in the Statement of Special Inspections and Chapter 17 of the IBCNYS, and who is approved by the Code Enforcement Official (CEO).
1.3.2 The Testing Laboratory and individual technicians shall be approved by the CEO.
1.3.3 The Testing Laboratory shall maintain a full time licensed Professional Engineer or Structural Engineer on staff who shall certify all test reports. The Engineer shall be responsible for the training of the testing technicians and shall be in responsible charge of the field and laboratory testing operations.
6.19 01410-1 394.107.001 SECTION 01410
SPECIAL INSPECTIONS AND STRUCTURAL TESTING
1.3.4 The minimum qualifications for testing agency laboratory personnel, and the minimum technical requirements for equipment and procedures utilized in the testing and inspection of construction and materials used in construction shall comply with ASTM E329 (Latest Edition) Standard Specification for Agencies Engaged in Construction Inspection, Testing, or Special Inspection.
1.4 SUBMITTALS:
1.4.1 The Special Inspector and Testing Laboratory shall submit to the CEO for review a copy of their qualifications which shall include the names and qualifications of each of the individual inspectors and technicians who will be performing inspections or tests. The Testing Laboratory shall also submit to the CEO for review, in accordance with ASTM E329, a certificate of accreditation, including the scope of accreditation.
1.4.2 Approved Fabricators: Special Inspections are not required for work done on the premises of a fabricator registered and approved to perform such work without special inspection. See Section 1704.2.5 of the IBCNYS for conditions of approval.
1.4.2.1 Certificate of Compliance upon completion of fabrication. The “Fabricator’s Certificate of Compliance” form is provided with the Statement of Special Inspections.
1.5 CONTRACTOR RESPONSIBILITIES:
1.5.1 The Contractor shall cooperate with the Special Inspector and his agents so that the Special Inspections and testing may be performed without hindrance.
1.5.2 The Contractor shall review the Statement of Special Inspections and shall be responsible for coordinating and scheduling inspections and tests. The Contractor shall notify the Special Inspector or Testing Laboratory at least 5 days in advance of a required inspection or test. Uninspected work that required inspection may be rejected solely on that basis.
1.5.3 The Contractor shall provide incidental labor and facilities to provide access to the work to be inspected or tested, to obtain and handle samples at the site or at source of products to be tested, to facilitate tests and inspections, storage and curing of test samples.
1.5.4 The Contractor shall keep at the project site the latest set of construction drawings, field sketches, approved shop drawings, and specifications for use by the inspectors and testing technicians.
6.19 01410-2 394.107.001 SECTION 01410
SPECIAL INSPECTIONS AND STRUCTURAL TESTING
1.5.5 The Special Inspection program shall in no way relieve the Contractor of his obligation to perform work in accordance with the requirements of the Contract Documents or from implementing an effective Quality Control program. The Contractor’s quality control personnel shall first review all work that is to be subjected to Special Inspections.
1.5.6 The Contractor shall be solely responsible for construction site safety.
1.5.7 When required by the Statement of Special Inspection’s “Quality Assurance Plan” each Contractor responsible for the construction or fabrication of main seismic or wind force resisting systems, designated seismic systems, or seismic or wind resisting components shall submit to the CEO and the Owner a “Statement of Responsibility”. If required the Contractor’s “Statement of Responsibility” form is provided with the Statement of Special Inspections.
1.6 LIMITS ON AUTHORITY:
1.6.1 The Special Inspector or Testing Laboratory may not release, revoke, alter, or enlarge on the requirements of the Contract Documents.
1.6.2 The Special Inspector or Testing Laboratory will not have control over the Contractor’s means and methods of construction.
1.6.3 The Special Inspector or Testing Laboratory shall not be responsible for construction site safety.
1.6.4 The Special Inspector or Testing Laboratory has no authority to stop the work.
1.7 STATEMENT OF SPECIAL INSPECTIONS:
1.7.1 The Statement of Special Inspections will be prepared and maintained by the Registered Design Professional in Responsible Charge (RDP).
1.7.2 The Statement of Special Inspections shall be submitted with the application for Building Permit.
6.19 01410-3 394.107.001 SECTION 01410
SPECIAL INSPECTIONS AND STRUCTURAL TESTING
1.8 RECORDS AND REPORTS:
1.8.1 Detailed daily reports shall be prepared of each inspection or test and submitted to the Special Inspector. Reports shall be submitted to the Special Inspector within 5 days of the inspection or test. The “Special Inspection Daily Report” form is provided with the Statement of Special Inspections. Daily reports shall include:
a. Project Name and Location, b. Date of test or inspection, c. Time of inspection start and end, d. Type of inspection “Continuous” or “Periodic”, e. Name of inspector or technician, f. Location of specific areas tested or inspected, g. Description of test or inspection and results, h. Applicable ASTM standard(s), i. Weather conditions, j. Current item(s) of construction needing corrective action, k. Previously reported items of construction requiring corrective action that have been corrected, l. Previously reported items of construction requiring corrective action that have not been corrected, m. Changes to Contract Documents authorized by the RDP, n. Engineer’s seal and signature.
1.8.2 The Special Inspector shall submit interim reports to the CEO, the Special Inspection Coordinator, the RDP, and the Contractor at the end of each week. The interim report(s) shall include all inspections and test reports received that week along with a completed “Special Inspection Weekly (Interim) Report” form provided with the Statement of Special Inspections.
1.8.3 Any discrepancies from the Contract Documents found during a Special Inspection shall be immediately reported to the Contractor for correction. If the discrepancies are not corrected, the Special Inspector shall notify the CEO, Special Inspection Coordinator, and the RDP by telephone, email, or fax. Reports shall document all discrepancies identified, exact location, reference to applicable plan sheets, details and specifications and the resolution or corrective action taken.
1.8.4 The Testing Laboratory shall immediately notify the Special Inspector, Special Inspection Coordinator, the RDP and the Contractor by telephone, email, or fax of any test results that fail to comply with the requirements of the Contract Documents.
6.19 01410-4 394.107.001 SECTION 01410
SPECIAL INSPECTIONS AND STRUCTURAL TESTING
1.8.5 Upon completion of the work requiring Special Inspections, each inspection agency and testing laboratory shall provide a statement to the Special Inspector that all work was completed in conformance with the Contract Documents and that all appropriate inspections and tests were performed.
1.9 FINAL REPORT OF SPECIAL INSPECTIONS:
1.9.1 The “Final Report of Special Inspections” shall be completed by the Special Inspector and submitted to the CEO prior to the issuance of a Certificate of Use and Occupancy. Concurrent with submission of the “Final Report of Special Inspections” to the CEO, the “Final Report of Special Inspections” shall be submitted to the Special Inspection Coordinator, and the RDP. The “Final Report of Special Inspections” form is provided with the Statement of Special Inspections.
1.9.2 The “Final Report of Special Inspections” will certify that all required inspections have been performed and the report will itemize any discrepancies that were not corrected or resolved.
PART 2 – PRODUCTS
(NOT USED)
PART 3 – EXECUTION
(NOT USED)
END OF SECTION
6.19 01410-5 394.107.001 Statement of Special Inspections
Project: 394.107.001 – Development Authority of the North Country Southern Expansion Location: Rodman, New York Owner: Jefferson County Address: 23400 NYS Route 177, Rodman, New York
Registered Design Professional in Responsible Charge: Matthew C. Fuller
This Statement of Special Inspections is submitted as a condition for permit issuance in accordance with the Special Inspection and Structural Testing requirements of the 2015 International Building Code as amended by New York State (IBCNYS). It includes a schedule of Special Inspection services applicable to this project as well as the name of the Special Inspection Coordinator and the identity of other approved agencies to be retained for conducting these inspections and tests. This Statement of Special Inspections encompass the following disciplines:
Structural Mechanical/Electrical/Plumbing Architectural Other:
The Special Inspection Coordinator shall keep records of all inspections and shall furnish inspection reports to the Building Code Enforcement Official (CEO) and the Registered Design Professional in Responsible Charge (RDP). Discovered discrepancies shall be brought to the immediate attention of the Contractor for correction. If such discrepancies are not corrected, the discrepancies shall be brought to the immediate attention of the CEO, the RDP in Responsible Charge and the Special Inspection Coordinator. The Special Inspection program does not relieve the Contractor of his or her responsibilities as defined in the Contract Documents.
Interim reports shall be submitted to the CEO and the RDP in Responsible Charge at a frequency as noted below. Detailed daily Special Inspection reports shall be submitted to the Special Inspector within (5) five days of item inspected.
When required by the Statement of Special Inspection’s “Quality Assurance Plan” each Contractor responsible for the construction or fabrication of main seismic or wind force resisting systems, designated seismic systems, or seismic or wind resisting components shall submit to the CEO and the Owner a Statement of Responsibility. The Contractor’s Statement of Responsibility form is provided with this Statement of Special Inspections.
Each approved fabricator that is exempt from Special Inspection of shop fabrication and implementation procedures per section 1704.2.5 of the IBCNYS must submit a Fabricator’s Certificate of Compliance at the completion of fabrication. The Fabricator’s Certificate of Compliance form is provided with this Statement of Special Inspections.
A Final Report of Special Inspections documenting completion of all required Special Inspections, testing and correction of any discrepancies noted in the inspections shall be submitted prior to issuance of a Certificate of Use and Occupancy. The Final Report of Special Inspections form is provided with this Statement of Special Inspections
Job site safety and means and methods of construction are solely the responsibility of the Contractor.
Interim Report Frequency: Weekly (a weekly report form is provided or per attached schedule. with this Statement of Special Inspections) Prepared by:
Matthew C. Fuller, P.E.
(type or print name)
Signature Date Design Professional Seal
Owner’s Authorization: Building Code Enforcement Official’s Acceptance:
Signature Date Signature Date
Page 1 of 9 Schedule of Inspection and Testing Agencies
This Statement of Special Inspections / Quality Assurance Plan includes the following building systems:
Soils and Foundations Spray Fire Resistant Material Cast-in-Place Concrete Wood Construction Precast Concrete Exterior Insulation and Finish System Masonry Mechanical & Electrical Systems Structural Steel Architectural Systems Cold-Formed Steel Framing Special Cases
Special Inspection Agencies Firm Address, Telephone, e-mail 1. Special Inspection BARTON & LOGUIDICE, D.P.C. 443 Electronics Parkway Coordinator (B&L) Liverpool, NY 13088 (315) 457-5200
2. Geotechnical Testing Agency TBD
3. Concrete Testing Agency TBD
4. Masonry Testing Agency TBD
5. Structural Steel Inspection TBD Agency
Note: The inspectors and testing agencies shall be independent of the Contractor or Subcontractor whose work is to be inspected or tested. Any conflict of interest must be disclosed to the Building Official, prior to commencing work. Page 2 of 9 Qualifications of Inspectors & Testing Technicians
The qualifications of all personnel performing Special Inspection activities are subject to the approval of the Building Official. The credentials of all Inspectors and testing technicians shall be provided.
MINIMUM QUALIFICATIONS FOR SPECIAL INSPECTORS CATEGORY MINIMUM QUALIFICATIONS
Reinforced 1. Current ICC Reinforced Concrete Special Inspector or ACI Concrete Construction Inspector Concrete 2. Concrete field testing can be by an ACI Concrete Field Testing Technician with Grade 1 certification. 3. Engineer-in-Training (EIT) with relevant experience. 4. New York State Registered Design Professional Engineer (RDP) with relevant experience. Prestressed 1. Precast Concrete; Current ICC Reinforced Concrete certification, and ICC prestressed concrete Concrete certification, and ACI Concrete Field Testing Technician with Grade 1 certification plus one year of relevant experience. 2. Engineer-in-Training (EIT) with relevant experience. 3. RDP with relevant experience. Welding 1. Current AWS Certified Welding Inspector. 2. Current ICC Structural Steel and Welding Certificate plus one year of relevant experience. 3. Current Level II certification from the American Society for Non-Destructive Testing (NDT). 4. Current NDT Level III provided previously certified as NDT Level II. High-Strength 1. Current ICC Structural Steel and Welding certification and one year of relevant experience. Bolting & Steel 2. Engineer-in-Training (EIT) with relevant experience. Frame 3. RDP with relevant experience. Inspection Masonry 1. Current ICC Structural Masonry certification and one year of relevant experience. 2. Engineer-in-Training (EIT) with relevant experience. 3. RDP with relevant experience. Excavation and 1. Current Level II certification in geotechnical engineering technology/construction from the Filling; National Institute for Certification in Engineering Technologies (NICET). Verification of 2. Engineer-in-Training (EIT) with relevant experience. Soils 3. RDP with relevant experience.
Wood 1. Special Inspector approved by the Building Code Enforcement Official. Construction 2. Engineer-in-Training (EIT) with relevant experience. 3. RDP with relevant experience.
Inspection of 1. Precast Concrete; Current ICC Reinforced Concrete certification plus one year of relevant Fabricators experience. 2. Structural Steel: see welding requirements. 3. Pre-fabricated Wood Trusses; Special Inspector approved by the Building Code Enforcement Official.
Page 3 of 9 Quality Assurance Plan
Quality Assurance for Seismic Resistance
Seismic Design Category B Quality Assurance Plan Required (Y/N) N
Description of seismic force resisting system(s), designated seismic system(s), and additional seismic system(s) and component(s):
Seismic Force Resisting System(s) – NA Designated Seismic System(s) – NA Additional Seismic System(s) and Component(s) – NA
Quality Assurance for Wind Requirements
Basic Wind Speed (3 second gust) 115 MPH Wind Exposure Category C Quality Assurance Plan Required (Y/N) N
Description of main wind force resisting system(s) and designated wind resisting component(s):
Main Wind Force Resisting System(s) – NA Designated Wind Resisting Components(s) - NA
Statement of Responsibility: NA
Each contractor responsible for the construction or fabrication of a system or component designated above must submit a Statement of Responsibility. Page 4 of 9 Qualifications of Inspectors and Testing Technicians
The qualifications of all personnel performing Special Inspection and testing activities are subject to the approval of the Building Official. The credentials of all Inspectors and testing technicians shall be provided if requested.
Key for Minimum Qualifications of Inspection Agents:
When the Registered Design Professional in Responsible Charge deems it appropriate that the individual performing a stipulated test or inspection have a specific certification or license as indicated below, such designation shall appear below the Agency Number on the Schedule.
PE/SE Structural Engineer – a licensed SE or PE specializing in the design of building structures PE/GE Geotechnical Engineer – a licensed PE specializing in soil mechanics and foundations EIT Engineer-In-Training – a graduate engineer who has passed the Fundamentals of Engineering examination with relevant experience.
American Concrete Institute (ACI) Certification
ACI-CFTT Concrete Field Testing Technician – Grade 1 ACI-CCI Concrete Construction Inspector ACI-LTT Laboratory Testing Technician – Grade 1&2 ACI-STT Strength Testing Technician
American Welding Society (AWS) Certification
AWS-CWI Certified Welding Inspector AWS/AISC-SSI Certified Structural Steel Inspector
American Society of Non-Destructive Testing (ASNT) Certification
ASNT Non-Destructive Testing Technician – Level II or III.
International Code Council (ICC) Certification
ICC-SMSI Structural Masonry Special Inspector with current registration, and one (1) year of relevant experience) ICC-SWSI Structural Steel and Welding Special Inspector ICC-SFSI Spray-Applied Fireproofing Special Inspector ICC-PCSI Prestressed Concrete Special Inspector ICC-RCSI Reinforced Concrete Special Inspector
National Institute for Certification in Engineering Technologies (NICET)
NICET-CT Concrete Technician – Levels I, II, III & IV NICET-ST Soils Technician - Levels I, II, III & IV NICET-GET Geotechnical Engineering Technician - Levels I, II, III & IV
Soils and Foundations NYSBC §1704.7, §1704.8, §1704.9 Page 5 of 9
SPECIAL SPECIAL Agency # Item Scope INSPECTION INSPECTION (Qualif.) a (CONTINUOUS) (PERIODIC)
1. Foundation #2 For Building Foundations/Structure Excavations Foundations verify soils below item of PE/GE construction for conformance with the EIT Contract Documents. Verify removal of NICET- unsuitable material and preparation of GET subgrade prior to placement of controlled fill. X Verify excavations have extended to proper foundation design depths in accordance with the Contract Documents.
2. Controlled #2 Prior to controlled fill/backfill placement Structural Fill below and adjacent to Item 1 (Granular Fill) PE/GE construction, perform classification and Classification EIT testing of each source of fill materials to NICET- verify compliance with the Contract X GET Documents.
3. Controlled #2 Prior to controlled fill/backfill placement Structural Fill below and adjacent to Item 1 (Granular Fill) PE/GE construction, and continuously during Placement EIT placement, verify placement lift thickness NICET- and compaction, and test density of each X GET compacted lift, to verify compliance with the Contract Documents.
a. “Periodic” rate of Special Inspection shall be defined as part-time or intermittent observation of work requiring Special Inspection by an approved Special Inspector who is present in the area where the work has been, or is being performed, and at the completion of work being observed, but prior to concealment. Specifically, “Periodic” Special Inspection shall begin at the commencement of an item to be inspected, at the mid-point of item construction, and at completion of item construction prior to concealment.
Cast-in-Place Concrete NYSBC §1704.4, §1708.3 Page 6 of 9
SPECIAL SPECIAL Agency # Item Scope INSPECTION INSPECTION (Qualif.) a (CONTINUOUS) (PERIODIC)
1. Mix Design #3 Verify prior to concrete placement ACI-CFTT that concrete mix to be placed ACI-CCI complies with the approved mix ICC-RCSI design and the Contract Documents PE/SE for the item being constructed. X EIT Construction covered includes building and structure foundations and walls, elevated floor slabs and beams, and equipment pads.
2. Reinforcement #3 Verify prior to concrete placement Installation that the size, spacing, cover, ACI-CCI positioning, condition, splices, and ICC-RCSI grade of reinforcing for Item 1 X PE/SE construction complies with the EIT Contract Documents. 3. Concrete #3 Continuously verify that placement Placement of concrete and concrete placement ACI-CCI techniques for Item 1 construction ICC-RCSI are in compliance with the Contract X PE/SE Documents. EIT 4. Sampling and #3 For Item 1 construction sample, test Testing of and report concrete slumps (ASTM Concrete ACI-CFTT C143), air-contents (ASTM C231 or ACI-CCI C173) and temperatures (ASTM X ICC-RCSI C1064) in accordance with the PE/SE Contract Documents. EIT 5. Formwork #3 Verify prior to concrete placement for Item 1 construction that ACI-CCI formwork shapes, locations, and X ICC-RCSI dimensions for concrete elements PE/SE being formed comply with the EIT Contract Documents. 6. Curing and #3 Verify prior to concrete placement, Protection and periodically during the specified ACI-CCI period of curing and protection, the ICC-RCSI means, methods, and maintenance of X PE/SE curing and protection of placed EIT concrete for Item 1 construction are in compliance with the Contract Documents. 8. In-place #3 Verify in-place concrete strength Concrete prior to removal of shores and forms Strength ACI-CFTT from beams and structural slabs ACI-CCI X ICC-RCSI PE/SE EIT
NYSBC §1704.5, Page 7 of 9 Masonry Required Inspection Level: A B C §1708.1, §1708.3
Agency # SPECIAL SPECIAL (Qualif.) Item Scope INSPECTION INSPECTION a (CONTINUOUS) (PERIODIC)
1. Mixing of #4 Verify prior to beginning masonry Mortar work, and periodically during the ICC-SMSI course of masonry work, that the PE/SE proportioning, mixing and re-tempering X EIT of mortar materials are in compliance with the Contract Documents. 2. Mixing of #4 Verify prior to beginning masonry Grout work, and periodically during the ICC-SMSI course of masonry work, that the X PE/SE proportioning, mixing of grout EIT materials are in compliance with the Contract Documents. 3. Installation of #4 Verify prior to beginning masonry work, Masonry and periodically during the course of ICC-SMSI masonry work, that the masonry unit PE/SE sizes, layouts, bonding, placements, and X EIT location of structural elements are in compliance with the Contract Documents. 4. Mortar Joints #4 Verify prior to beginning masonry work, and periodically during the course of ICC-SMSI masonry work, that the construction of X PE/SE mortar joints are in compliance with the EIT Contract Documents. 5. Reinforcement #4 Verify prior to beginning masonry work, Installation and periodically during the course of ICC-SMSI masonry work, that the size, grade, X PE/SE placement, positioning and lapping of EIT reinforcing steel are in compliance with the Contract Documents. 6. Grouting #4 Verify prior to beginning masonry work, Operations I and periodically during the course of ICC-SMSI masonry grouting, that the placement of PE/SE reinforcement, connectors, and anchors, X EIT etc, are in compliance with the Contract Documents. 7. Grouting #4 Verify prior to beginning masonry work, Operations II and continuously during the course of ICC-SMSI masonry grouting, that grout spaces are PE/SE clear of debris deleterious to grout X EIT material and grout bonding, consolidation, and placement are in compliance with the Contract Documents.
Required Inspection Level: A B C NYSBC §1704.5, Page 8 of 9 Masonry §1708.1, §1708.3
8. Protection of #4 Verify prior to masonry work, Masonry periodically during masonry Materials, and ICC-SMSI construction, and periodically during Constructed PE/SE the specified period of curing and Masonry EIT protection, that the means, methods, and X maintenance of curing and protection of masonry materials and completed masonry work is in compliance with the Contract Documents. 9. Evaluation of #4 For each 5000 sq. ft. of masonry wall, or Masonry fraction thereof, and whenever there is a Compressive ICC-SMSI change in mixture proportions, method Strength of mixing, or materials used, verify X masonry compressive strength(f’m)is in compliance with the Contract Documents. 10. Evaluation of #4 Test compressive strength of grout Grout Strength samples in accordance with ASTM ICC-SMSI C1019 prior to construction and for each 5000 sq. ft. of masonry wall or fraction thereof, and whenever there is a X change in mixture proportions, method of mixing, or materials used. Verify compressive strength of grout is in compliance with the Contract Documents. 11. Masonry #4 Verify anchor/tie sizes, locations, Anchorage spacings, embedments, and other details ICC-SMSI of anchorage of masonry to structural X PE/SE members. EIT
Structural Steel NYSBC §1704.6, §1707.3 Page 9 of 9
Agency # SPECIAL SPECIAL (Qualif.) Item Scope INSPECTION INSPECTION a (CONTINUOUS) (PERIODIC)
1. Material #5 Identify markings to conform to ASTM Verification of ICC-SWSI standards specified in the Contract High Strength PE/SE Documents. Manufacturer’s certificate Bolts, Nuts EIT of compliance is required. X and Washers
2. Inspection of #5 Verify that bolted connections have been High-Strength ICC-SWSI drawn together and properly snugged in Bolting (Snug- PE/SE accordance with AISC 360, Section Tight Type) EIT M2.5, and the RCSC “Specification for X Structural Joints Using ASTM A325 or A490 Bolts.
3. Material #5 Identify markings to conform to ASTM Verification of ICC-SWS standards specified in the Contract Structural PE/SE Documents. Manufacturer’s mill X Steel EIT certificate of compliance is required. 4. Material #5 Identify markings to conform to AWS Verification of ICC-SWS specification in the Contract Documents Weld Filler PE/SE and AISC 360, Section A3.5. X Materials EIT Manufacturer’s mill certificate of compliance is required 5. Inspection of #5 Multipass, and single pass fillet welds Welding I ICC-SWS greater than 5/16” in accordance with PE/SE the Contract Documents and AWS D1.1 X EIT
6. Inspection of #5 Single pass fillet welds less than or Welding II ICC-SWS equal to 5/16”, and floor and roof deck PE/SE welds in accordance with the Contract X EIT Documents and AWS D1.1
7. Inspection of #5 Inspection of joint details, including Steel Frame ICC-SWS details of bracing, stiffening, member (Including PE/SE locations, and application of joint X Roof Truss) EIT details at each location for compliance Details with the Contract Drawings
Contractor’s Statement of Responsibility
Each contractor responsible for the construction or fabrication of a system or component designated in the Quality Assurance Plan must submit a Statement of Responsibility.
Project:
Contractor’s Name:
Address:
License No.:
Description of designated building systems and components included in the Statement of Responsibility:
Contractor’s Acknowledgment of Special Requirements
I hereby acknowledge that I have received, read, and understand the Quality Assurance Plan and Special Inspection program.
I hereby acknowledge that control will be exercised to obtain conformance with the construction documents approved by the Building Official.
______Signature Date
Contractor’s Provisions for Quality Control
Procedures for exercising control within the contractor’s organization, the method and frequency of reporting and the distribution of reports is attached to this Statement.
Identification and qualifications of the person(s) exercising such control and their position(s) in the organization are attached to this Statement.
Fabricator’s Certificate of Compliance
Each approved fabricator that is exempt from Special Inspection of shop fabrication and implementation procedures per section 1704.2 of the IBCNYS must submit a Fabricator’s Certificate of Compliance at the completion of fabrication.
Project:
Fabricator’s Name:
Address:
Certification or Approval Agency:
Certification Number:
Date of Last Audit or Approval:
Description of structural members and assemblies that have been fabricated:
I hereby certify that items described above were fabricated in strict accordance with the approved construction documents.
______Signature Date
______Title
Attach copies of fabricator’s certification or building code evaluation service report and fabricator’s quality control manual
SPECIAL INSPECTION DAILY REPORT
City/County of Permit No.: Date:
Project Name/Address:
Inspection type(s) coverage:
Continuous Periodic
Inspection time: Beginning: Ending:
Describe inspections made, including locations:
Tests performed:
New Items needing correction:
Corrected items from previous reports:
Item corrections remaining incomplete:
Changes to approved plans authorized by registered design professional in responsible charge:
1 of 2
Comments:
To the best of my knowledge, work inspected was in accordance with the building department approved plans, specifications and applicable workmanship provisions of the IBCNYS except as noted above.
Signed: ______Inspection Agency: ______Print Full Name: ______ID / Certificate Number: ______
cc: Project Owner 2 of 2
SPECIAL INSPECTION WEEKLY (INTERIM) REPORT
City/County of Permit No.: Date:
Project Name/Address:
Total inspection time each day:
Date Hours Inspection Type Frequency (P or C) Location
P – Periodic inspection C – Continuous inspection
Describe inspections made, including locations:
Tests performed:
New Items needing correction:
Corrected items from previous reports:
Item corrections remaining incomplete:
Changes to approved plans authorized by registered design professional in responsible charge:
1 of 2
Comments:
To the best of my knowledge, work inspected was in accordance with the building department approved plans, specifications and applicable workmanship provisions of the IBC except as noted above.
Signed: ______Inspection Agency: ______Print Full Name: ______ID /Certificate Number: ______
cc: Project Owner 2 of 2
Final Report of Special Inspections
Project: Location: Owner: Owner’s Address:
Architect of Record: Structural Engineer of Record:
To the best of my information, knowledge and belief, the Special Inspections required for this project, and itemized in the Statement of Special Inspections submitted for permit, have been performed and all discovered discrepancies have been reported and resolved other than the following:
Comments:
(Attach continuation sheets if required to complete the description of corrections.)
Interim reports submitted prior to this final report form a basis for and are to be considered an integral part of this final report.
Respectfully submitted, Special Inspector
(Type or print name)
Signature Date Licensed Professional Seal
SECTION 02072
GEOTEXTILE
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Geotextile as shown on the Plans, as specified, and/or directed.
1.2 SUBMITTALS:
1.2.1 Prior to the installation or delivery of a geotextile, the Contractor shall submit to the Engineer, from the geosynthetic manufacturer, a list of guaranteed "minimum average roll values" (MARV) for the geotextile (the minimum average roll value is the minimum value obtained from the average values of the sampled rolls). The Contractor shall provide the Engineer, from the manufacturer, a written certification stating that the geosynthetic material meets or exceeds the guaranteed properties submitted.
1.2.2 In addition to submitting guaranteed physical properties, the Contractor shall submit to the Engineer, from the manufacturer, documentation demonstrating the chemical compatibility of the geosynthetic material with leachate generated from mixed municipal solid waste. Such documentation shall include chemical compatibility testing results.
1.2.3 Prior to delivery of the geotextile, the Contractor shall submit a sample of the warranty to be provided as described in Article 3.3.1.
1.2.4 Documentation must be provided by the manufacturer ensuring that each roll of Type 4 geotextile has been inspected for the presence of broken needles using an in-line metal detector.
1.3 DELIVERY:
1.3.1 All geotextiles will be inspected on delivery, and materials that do not comply with the Specification will be rejected. The Contractor shall furnish all labor required to handle the geotextiles during inspection and shall remove the rejected material from the site of the work.
1.4 CONFORMANCE TESTING:
1.4.1 Within one week of delivery and at the Engineer's direction, the Contractor shall provide the necessary labor, tools and equipment to obtain samples and send these samples to an independent quality assurance laboratory for testing at the Contractor's expense. At a minimum, the following tests will be performed on Type 1, Type 2, and Type 4 geotextiles:
6.19 02072-1 394.107.001 SECTION 02072
GEOTEXTILE
- mass per unit area - ASTM D5261 - grab strength - ASTM D4632 - puncture strength - ASTM D4833 - trapezoidal tear strength - ASTM D4533
1.4.2 Samples will be taken by cutting along the width and 5 feet from the end of a rolled or folded geotextile material. The sampling frequency for the geotextile will be one sample per every 100,000 square feet of respective material delivered.
1.4.3 Any samples which fail the conformance testing will require the failed material to be removed from the site and replaced with new material at the Contractor's expense.
1.4.4 For each lot number of geotextile (Type 1, Type 2, and Type 4) that arrives at the site, a sample shall be taken by the Contractor and provided to the Owner for archiving. This sample shall be 3 feet long by the width of the rolled or folded geotextile.
1.4.5 Conformance testing for Type 3 Geotextile is not required.
1.4.6 Conformance tests may be taken at manufacturing facility with Engineer’s approval. If the Contractor elects to take conformance samples at the manufacturer’s facility rather than on- site in the presence of the Engineer, the Contractor shall provide chain of custody forms from the sampling location to the independent laboratory to the site. All conformance test results shall be submitted a minimum of seven days prior to installation. No materials shall be installed until acceptable test results are approved by the Engineer.
PART 2 - PRODUCTS
2.1 MATERIALS:
2.1.1 Geotextile:
2.1.1.1 Type 1, Type 2, and Type 4 geotextile shall be nonwoven, needle-punched, polymeric geotextile. Type 3 geotextile shall be woven geotextile. The fibrous structure of the geotextile must be able to withstand handling, placement and long-term loads associated with the incorporated Specifications.
2.1.1.2 All geotextile shall be protected from ultraviolet light, precipitation, mud, dirt, excessive dust, puncture, cutting and/or other damaging condition prior to and during delivery.
6.19 02072-2 394.107.001 SECTION 02072
GEOTEXTILE
All geotextile shall be capable of withstanding 30 days of sunlight without measurable deterioration.
2.1.1.3 Three types of nonwoven geotextiles will be supplied by the Contractor for use in landfill construction. Fabrics shall be similar materials except for the weight and the associated physical properties. Type 1 will be nominal eight oz./square yard or heavier, and Type 2 will be a nominal sixteen oz./square yard or heavier fabric. Type 4 will be a nominal twenty-four oz./ square yard or heavier fabric. An equivalent substitution may be made subject to the approval of the Engineer. Geotextile Specifications are given in Paragraph 2.2.
2.1.1.4 One type of woven geotextile will be supplied by the Contractor for use in roadway construction. Type 3 geotextile shall have a typical puncture strength of 150 lb according to ASTM D4833. Type 3 geotextile shall be Mirafi 600X, or approved equal.
2.1.1.5 All geotextiles shall be delivered on site in rolls contained within opaque plastic covers. These rolls will be tagged and display the following information.
- Manufacturer's name - Product identification - Lot number - Roll number and dimensions
2.2 SPECIFIED VALUES:
2.2.1 Geotextile Specifications:
2.2.1.1 The table below lists the MARV specification values for the geotextiles to be used for the project. In addition, the typical average specification values, as indicated, have been listed. Final approval of the geotextile properties shall be made by the Engineer based upon Contractor's submittals.
6.19 02072-3 394.107.001 SECTION 02072
GEOTEXTILE
Geotextiles Specification Limit Test Property Type 1 Type 2 Type 3 Type 4 Method
*Mass per Unit 8.0 16.0 NA 24.0 ASTM D5261 Area (oz/yd2)
**Apparent Opening 70-100 80-100 80-100 100 CW-02215 or Size (US Sieve) ASTM D4751
*Grab Strength (lbs) 205 370 315 500 ASTM D4632
*Grab Elongation (%) 50 50 12 50 ASTM 04632
*CBR Puncture Resistance 535 1080 900 1100 ASTM D6241 (lbs)
*Trapezoidal Tear 85 145 110 200 ASTM D4533 Strength (lbs)
*Permittivity (sec-1) 1.35 0.6 0.05 0.4 ASTM D4491
*Water Flow Rate 90 40 4 25 ASTM D4491 (gpm/ft2)
*MARV Values Taken Along Weakest Principal Direction. **Typical Average Values NA = Not Applicable
PART 3 - EXECUTION
3.1 GEOTEXTILE INSTALLATION:
3.1.1 The following procedures and requirements will be followed during the installation of geotextile.
6.19 02072-4 394.107.001 SECTION 02072
GEOTEXTILE
3.1.2 Placement:
3.1.2.1 The placement of the geotextile shall not be conducted during adverse weather conditions. The geotextile will be kept dry during storage and up to the time of deployment. All geotextiles will be secured with sandbags or an equivalent approved anchoring system. Removal of the sandbags or equal will only occur upon placement of an overlying soil layer.
3.1.2.2 Proper cutting tools shall be used to cut and size the geotextile materials. Extreme care will be taken while cutting in-place geotextiles.
3.1.2.3 During the placement of geotextiles, all dirt, dust, sand or mud shall be kept off to prevent clogging. If excessive contaminant materials are present on the geotextile, it shall be cleaned or replaced as directed by the Engineer.
3.1.2.4 No equipment used will damage the geotextiles by handling, trafficking or other means. Equipment, including ATVs, will not be allowed to travel directly on the geotextiles during the installation of overlying soils or geosynthetic layers, unless otherwise approved by the Engineer. Any damage to the material from the equipment shall be repaired by the Contractor at no additional cost to the Owner.
3.1.2.5 The Contractor shall perform field needle detection for all Type 4 geotextile rolls placed on the job site. Each roll shall also be visually inspected for sheet defects prior to primary collection layer placement.
3.1.3 Seaming or Joining:
3.1.3.1 Geotextiles:
3.1.3.1.1 Geotextiles shall be seamed using either an eighteen inch overlap, by sewing or by fusion welding. The specific conditions requiring a sewn/welded seam or simply an overlap are as follows:
a. Type 1 and Type 3 geotextile shall be sewn or overlapped according to the criteria below. Type 2 and Type 4 geotextile shall be sewn or fusion welded with a micro welder.
b. In all cases, seams on side slopes will be parallel to the line of slope and sewn or fusion welded 5 feet from the toe-of-slope upward over the length of the slope and
6.19 02072-5 394.107.001 SECTION 02072
GEOTEXTILE
into the anchor trench. No horizontal seams will be allowed on side slopes, except for patching.
c. Geotextiles placed on the subgrade, or between two soil layers at less than 10 percent slope may utilize an 18-inch overlap seam. d. Where the slope is greater than 10 percent, and/or directly above a geomembrane, these seams shall be sewn or fusion welded as stated above.
3.1.3.1.2 Sewing will be done using a polymeric thread with chemical compatibility resistance equal to or exceeding the geotextile being sewn. Thread and the sewing device shall be approved by the Engineer prior to its use in the field.
3.1.3.1.3 Repair of tears or holes in the geotextile will require the following procedures:
a. On slopes: A patch made from the same geotextile will be double seamed into place; with each seam 1/4-inch to 3/4-inch apart and no closer than 1-inch from any edge. Should any tear exceed 10% of the width of the roll, that roll will be removed from the slope and replaced.
b. Flat slopes: A patch made from the same geotextile will be spot-seamed in place with a minimum of 24-inch overlap in all directions.
3.2 POST-CONSTRUCTION:
3.2.1 Upon completion of the installation, the Contractor shall submit to the Engineer:
a. All quality control documentation.
b. The warranty obtained from the Manufacturer/Fabricator.
3.3 WARRANTY:
3.3.1 The Contractor shall obtain and submit to the Owner from the manufacturer a standard warranty provided for the geotextiles. The warranty shall guarantee that the geotextile shall remain free from defects for a minimum of one (1) year from the date of substantial completion of the project. The Engineer will review the warranty for completeness prior to the Owner accepting its provisions.
6.19 02072-6 394.107.001 SECTION 02072
GEOTEXTILE
PART 4 – MEASUREMENT & PAYMENT
4.1 MEASUREMENT – GEOTEXTILE:
4.1.1 Measurement of the quantity of Geotextile, allowed for payment shall be based on the number of square feet placed as measured to the nearest one foot of Geotextile placed excluding any overlaps and materials in the anchor trench, in accordance with the Specifications, Drawings or as approved by the Engineer.
4.2 PAYMENT – GEOTEXTILE:
4.2.1 For Geotextile, not included in other unit or lump sum price items, payment for Geotextile will be made at the applicable price stated in the Bid.
4.2.2 The Owner will pay for materials delivered and properly stored on-site upon receipt of all required submittals and conformance test results. After installation of the material, the Owner shall retain 10 percent of the price of the geotextile until the Contractor provides an acceptable warranty.
END OF SECTION
6.19 02072-7 394.107.001 SECTION 02081
PETROLEUM BULK STORAGE TANK REMOVAL AND CLOSURE
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials, supervision and equipment for underground Petroleum Bulk Storage Tank Removal and Closure, in accordance with all applicable laws, rules and regulations, as shown on the Plans, as specified and/or directed.
1.2 REFERENCES:
1.2.1 The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only. The publications are identified for information only, and do not represent all regulations, codes, or standards which may apply to this work.
1.2.1.1 New York State Department of Environmental Conservation (NYSDEC) Publications:
6 NYCRR Part 613 Petroleum Bulk Storage
6 NYCRR Parts 596-599 Chemical Bulk Storage
DER-10 Technical Guidance for Site Investigation and Remediation
1.2.1.2 United States Environmental Protection Agency (USEPA) Regulation:
40 CFR Part 280 Technical Standards and Corrective Action Requirements for Owners and Operators of Underground Storage Tanks (USTs)
1.2.1.3 American Petroleum Institute (API) Publications:
Publ. 1604 Closure of Underground Petroleum Storage Tanks
Publ. 2015 Requirements for Safe Entry and Cleaning of Petroleum Storage Tanks
Publ. 1631 Interior Lining of Underground Storage Tanks
6.19 02081-1 394.107.001 SECTION 02081
PETROLEUM BULK STORAGE TANK REMOVAL AND CLOSURE
Publ. 2217A Safe Work in Inert Confined Spaces in the Petroleum and Petrochemical Industries
Publ. 2219 Safe Operation of Vacuum Trucks Handling Flammable and Combustible Liquids in Petroleum Service
1.2.1.4 Occupational Safety and Health Administration (OSHA) Regulations:
29 CFR Part 1910.134 Respiratory Protection 29 CFR Part 1910.146 Permit-Required Confined Spaces 29 CFR Part 1910.650-652 Excavations and Trenching Operations
1.2.1.5 National Fire Protection Association, Inc. (NFPA) Publications:
30 Flammable and Combustible Liquids Code
30A Code for Motor Fuel Dispensing Facilities and Repair Garages
69 Standard on Explosion Prevention Systems
77 Recommended Practice on Static Electricity
306 Standard for the Control of Gas Hazards on Vessels
326 Standard for the Safeguarding of Tanks and Containers for Entry, Cleaning, or Repair
327 Standard Procedures for Cleaning or Safeguarding Small Tanks and Containers
1.2.1.6 International Fire Code:
23 Motor Fuel-Dispensing Facilities and Repair Garages
50 Hazardous Materials – General Provisions
57 Flammable and Combustible Liquids Code
6.19 02081-2 394.107.001 SECTION 02081
PETROLEUM BULK STORAGE TANK REMOVAL AND CLOSURE
1.3 GENERAL DESCRIPTION:
1.3.1 Under this Item, Contractor shall provide all labor and materials required for the excavation of tanks and associated structures, tank sludge removal and disposal, tank and piping cleaning, tank and piping demolition, and backfilling associated with the closure of petroleum bulk storage tanks as identified on the Plans or as specified.
1.4 RELATED WORK:
1.4.1 All earthwork shall be in accordance with Section 02218, “Excavation”; and Section 02222, “Granular Fill”.
1.5 SUBMITTALS:
1.5.1 Tank Closure Plan: The Contractor shall submit a written tank closure plan for the closure of petroleum bulk storage tanks at the site. The tank closure plan shall identify the proposed schedule and tasks required for closure of the tanks identified on the Plans. The tank closure plan shall highlight modifications to standard operating procedure required due to site specific features. The plan shall include a sketch identifying the limits of the area required for the Contractor’s equipment, and means and methods to brace, support and protect any underground utilities within the vicinity of excavation work. The Contractor is responsible for field location of all utilities prior to excavation.
1.5.2 Waste Disposal: All solid wastes generated from tank removal shall be disposed of at the active working face of the onsite landfill in accordance with the facility’s permit. At the Owner’s request, material must be weighed across the facility truck scale and the disposal tonnage recorded. Tipping fees will not be assessed for approved material disposed at the onsite landfill facility. Any recyclable materials shall be transported to an approved recycling facility.
The Contractor shall submit:
a. A list of the proposed permitted disposal sites and facilities for the ultimate disposal of tank sludge. b. Copies of operating permits for facilities identified above. c. Waste Transporter Permits for all vehicles to be used for the project. d. Certified scale house to be utilized for weighing wastes. e. Copies of all shipping manifests, bills of lading, etc., for tank sludges transported for disposal. f. Tank Clean Certificate.
6.19 02081-3 394.107.001 SECTION 02081
PETROLEUM BULK STORAGE TANK REMOVAL AND CLOSURE
1.5.3 Safety Plans: Contractor shall submit the following written safety plans prior to initiating on-site work:
a. Health & Safety Plan b. Confined Space Safety Plan c. Trenching & Excavation Safety Plans
1.5.4 Confined Space Entry Permits: Contractor shall submit copies of all confined space entry permits to the Owner weekly.
1.6 REGULATORY AND SAFETY REQUIREMENTS:
1.6.1 Comply with Federal, State, and local regulations governing the handling, transport, and disposal of bulk storage tanks, petroleum and petroleum contaminated products, and non- hazardous and hazardous wastes.
1.7 PROTECTION:
1.7.1 Facilities: Protect electrical and mechanical services and utilities. Where removal of existing utilities is required to complete the work, provide written Notice of Interruption and approved temporary services or connections for electrical and mechanical utilities.
1.8 RELOCATIONS:
1.8.1 Perform temporary relocation of utilities and site features located adjacent to the work area which will impair the tank removal. Relocation of all existing utilities and site features must be approved and coordinated with the Engineer and Owner. Perform the removal and reinstallation of approved items with workmen skilled in the trades involved. Repair items to be relocated which are damaged or replace damaged items with new undamaged items, at no additional expense to the Owner, and as approved by the Engineer.
PART 2 - PRODUCTS
NOT USED
6.19 02081-4 394.107.001 SECTION 02081
PETROLEUM BULK STORAGE TANK REMOVAL AND CLOSURE
PART 3 - EXECUTION
3.1 NOTIFICATION:
3.1.1 The Contractor shall notify the local Fire Marshal and local building codes office of the intent to conduct the tank removals 30 days prior to the work and shall notify the Engineer at least 72 hours prior to commencing Petroleum Bulk Storage Tank Removal and Closure activities. Notification of the New York State Department of Environmental Conservation will be coordinated with the submittal of a Pre-Work Notification for Bulk Storage (PBS or CBS) Tank Installation or Closure form identifying removal of the tanks to be submitted by the Contractor 30 days prior to the planned work with a copy also provided to the Engineer. The PBS Registration form will be prepared by the Engineer or Owner documenting the closure of the tanks following the removal and closure.
3.2 SCHEDULING:
3.2.1 All storage tank closure and removals shall be scheduled during normal work hours.
3.3 PETROLEUM CONTAMINATED FLUIDS:
3.3.1 Residual Tank Fluids: Prior to cleaning the tank, the Contractor shall coordinate with the Owner for the removal of all remaining fluids in the tank. All usable fluids will be removed by the Owner for use. The cost for the removal, testing, transport, and disposal of any remaining tank fluids, sludges, and fluids generated as part of the tank and piping cleaning process shall be included in the base bid. All materials removed from the tanks shall be collected and containerized for disposal at a properly permitted facility in accordance with local, State and Federal regulations.
3.4 SITE PREPARATION:
3.4.1 Contractor shall not begin work until the project areas are demarcated and work area provided with wooden barricades to prevent pedestrian access, all nearby utilities are identified, and temporary chain link construction fencing has been installed to protect the works areas and all open excavations.
3.4.2 Utilities: Building utilities may exist within the vicinity of the tank removal areas which are not identified on the Plans. Contractor will coordinate the identification of existing buried utilities with Owner’s representatives, and underground utility locating services in the area. Contractor will be responsible for repair or any damage to existing utilities, at no additional cost to the Owner.
6.19 02081-5 394.107.001 SECTION 02081
PETROLEUM BULK STORAGE TANK REMOVAL AND CLOSURE
3.4.3 Surface Preparation: Contractor shall remove topsoil (if applicable), and saw cut existing pavements and concrete within all work areas. If concrete items require removal to complete the work (e.g. curbing, sidewalks, etc.), the Contractor shall provide replacement items to match existing or improved conditions.
3.5 TANK AND PIPING REMOVALS:
3.5.1 Petroleum Storage Tank Cleaning: The Contractor shall access the tank top, remove remaining tank fluids (if necessary), purge and test atmospheres, access the tank, clean tank interior, and mop dry. All sludges and wash fluids generated during the flushing and cleaning shall be captured and disposed of in accordance with local, State and Federal regulations, and shall be included in the Base Bid. The tank sludges and solids encountered during cleaning that cannot be disposed of with the fluids shall be removed and disposed of in accordance with the laws, regulations, and guidelines as identified above.
3.5.2 Piping and Equipment Removal: Prior to the removal of the petroleum piping and equipment, Contractor shall remove excess fluids from all piping, containment systems, and equipment and flush and clean thoroughly. All sludges and wash fluids generated during the flushing and cleaning shall be captured and disposed of in accordance with local, State and Federal regulations, and shall be included in the Base Bid. The pipes, equipment, and solids encountered during cleaning shall be removed and disposed of in accordance with the laws, regulations, and guidelines as identified above.
3.5.3 Petroleum Storage Tank Removal and Closure: The Contractor shall close and remove tanks and appurtenances including, but not limited to: the tank, pumps and piping systems, all fittings, all piping from the tanks to the equipment serviced as indicated on the Plans, dispensing island and related equipment, all associated vent piping, fill and monitoring manhole connections, manholes, containment piping and sumps, tank monitoring and gauging systems, grounding systems, cathodic protection, tank top structures, and all anchorage systems. Soil located in the proximity of building foundations, and or utilities shall not be removed so as to undermine the integrity of these installations. All removal activities shall be conducted in accordance with local, State and Federal regulations.
3.5.4 Soil Assessment: Engineer will utilize and provide a photoionization detector (PID) capable of detecting the presence of petroleum vapors during the tank removal. The PID shall be utilized to screen soils located in proximity to the petroleum tank and piping systems for the presence of petroleum vapors during tank excavation. The screening will be conducted on successive 2 foot lifts removed from the ground.
6.19 02081-6 394.107.001 SECTION 02081
PETROLEUM BULK STORAGE TANK REMOVAL AND CLOSURE
3.5.5 Tank or piping Pit Assessment: Following the removal of the tank or piping from the ground, the Engineer will conduct an assessment of the excavation side walls and bottom. A PID will be utilized to assess the presence of residual petroleum contaminated soils located in the excavation. Once the absence of significant contamination has been confirmed with the PID, the Engineer will obtain representative samples of the soil from the four sidewalls and bottom of each tank or piping excavation. The actual location of the samples shall be determined in the field, based on the site conditions, and under the direction of the Engineer. The soil samples from the tank pit will be submitted by the Engineer to a New York State Department of Health approved laboratory for analysis of petroleum compounds.
3.5.6 Backfilling: Contractor shall provide backfill for the tank or piping pit excavation in accordance with Section 02218, “Excavation” and Section 02222, “Granular Fill”. Final surfaces should be returned to the condition existing prior to removal of the tank or piping, unless otherwise noted on the Plans.
3.6 DISPOSITION OF MATERIALS:
3.6.1 Tank and Petroleum Wastes: Contractor shall remove and dispose of the tank, accessories, piping, steel and concrete associated with the removal of the tank at the onsite landfill working face. All liquid petroleum related wastes shall be removed for disposal as identified in the Submittals.
3.6.2 Petroleum Contaminated Fluids: Contractor shall provide for all containerization, testing, staging, loading, transport, treatment and disposal of petroleum contaminated fluids required to complete the project.
3.7 CLEANUP:
3.7.1 Remove and transport all non-petroleum related debris and rubbish in a manner that will prevent spillage in buildings, parking lots, and adjacent areas. Contractor will remove debris for disposal at the landfill working face.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT – PETROLEUM BULK STORAGE TANK REMOVAL AND CLOSURE:
6.19 02081-7 394.107.001 SECTION 02081
PETROLEUM BULK STORAGE TANK REMOVAL AND CLOSURE
4.1.1 Measurement for Petroleum Bulk Storage Tank Removal and Closure shall include the cost of all materials, equipment, replacement backfill of non-contaminated soils and tank void, tank, sludge and fluids transport and disposal fees, labor, submittals, and testing required to complete the work.
4.2 PAYMENT – PETROLEUM BULK STORAGE TANK REMOVAL AND CLOSURE:
4.2.1 Payment for Petroleum Bulk Storage Tank Removal and Closure, not included in other unit or lump sum price items, payment for Petroleum Bulk Storage Tank Removal and Closure will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 02081-8 394.107.001 SECTION 02218
EXCAVATION
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Excavation, as shown on the Plans, specified, and/or directed.
1.1.2 Excavation, in open cut, includes the loosening, removing, transporting, storage and disposal of all materials necessary to be removed for the construction and completion of all work under the Contract. Excavations shall be made to the widths and depths shown on the Plans, specified or directed.
1.1.3 Where rock is encountered, the excavations shall be done in accordance with the applicable provisions hereof.
1.2 DEFINITIONS:
1.2.1 The term "excavation" and the term "trenching" where used, shall be deemed and understood to cover the following described work, and the price bid for any and all items including "excavation", or "trenching" shall be deemed to include and cover all of the several following detailed operations:
- The loosening, removing, transporting, storage and rehandling of all materials;
- All sheeting, sheetpiling, bracing and shoring, and the placing, driving, cutting off and removing of the same;
- All diking, ditching, fluming, cofferdamming, pumping, well-pointing, bailing, dewatering and draining or otherwise disposing of water (surface and subsurface);
- The refilling of trenches, excavations and pits, and the furnishing and placing of material over trenches, excavations and pits to the original surface of the ground or to other grades as may be shown or directed;
- The compacting of all materials used in filling or refilling by rolling, ramming, watering, puddling, etc., as may be required;
- The removing and disposing of all surplus materials from all excavations in the manner specified;
11.13 02218-1 SECTION 02218
EXCAVATION
- The maintenance, accommodation and protection of travel;
- The supporting and protecting of all tracks, rails, buildings, curbs, sidewalks, pavements, overhead wires, poles, trees, vines, shrubbery, pipes, sewers, conduits or other structures or property and its appurtenances, in the vicinity of the work, whether over or underground or which appear within the excavations, and the restoration of the same in case of settlement or other injury;
- All temporary bridging and fencing and the removing of same, the temporary paving of highways, roads, driveways, and the permanent repairing or replacing and relaying of pavements, curbs, gutters and sidewalks removed, disturbed, or injured, the removing and clearing away of all construction rubbish, refuse, unused materials, plant and tools from the site;
- The dressing, topsoiling, sodding and/or seeding of all unpaved areas disturbed by the Contractor within and outside the limits of the Contract as may be necessary to leave the surface in as good condition as it was previous to the commencement of the work.
1.2.2 "Earth" includes all materials, such as sand, gravel, clay loam, pavements, ashes, cinders, muck, roots, or pieces of timber, soft or disintegrated rock, not requiring blasting, barring or wedging from their original beds, and specifically excludes all ledge or bed rock, and individual boulders or masonry larger than one-half cubic yard in volume.
1.2.3 "Backfill" includes selected materials for the backfilling or refilling of all excavations and trenches up to the original surface of the ground or to other grades as may be shown or directed.
1.2.4 "Spoil" includes surplus excavated materials not required or not suitable for backfills or embankments.
1.2.5 "Embankments" include fills constructed of selected materials above the original surface of the ground.
1.2.6 "Rock" includes ledge or bedrock requiring barring or wedging from their original beds and individual boulders or masonry larger than one-half cubic yard in volume.
11.13 02218-2 SECTION 02218
EXCAVATION
PART 2 - PRODUCTS
2.1 SOIL MATERIALS: Where used for general site fill, soil material shall be free of debris, roots, wood, scrap material, vegetable matter, refuse, soft unsound particles, frozen, deleterious, or objectionable materials.
2.2 CONTROLLED FILL: Provide where indicted and also within building lines and under concrete slabs and aprons. Fill to be granular fill as specified in Section 02222.
PART 3 - EXECUTION
3.1 ROCK EXCAVATION:
3.1.1 Rock excavation shall include the loosening, removing, transporting, storing and disposal of all materials requiring blasting, barring, or wedging for removal from their original beds. All pieces of ledge or bed rock and boulders or masonry larger than one-half (1/2) cubic yard in volume are included under rock excavation. Rock excavations shall be made to the widths and depths shown on the Plans or as directed by the Engineer. For concrete structures, rock shall be excavated only to the bottom of the structure unless otherwise shown or noted on drawings. All excavated rock which cannot be handled and compacted as earth shall not be mixed with other backfill or embankment materials except as specified herein or as directed.
3.1.2 Blasting will not be permitted.
3.2 EXCAVATION FOR STRUCTURES:
3.2.1 Excavation shall be of sufficient size, and only of sufficient size, to give suitable room for the proper construction of structures and appurtenances, including allowances for sheeting, dewatering, and other similar work necessary for completion of the Contract.
3.2.2 Excavations for structures shall be made only to the lines and grades shown on the Plans, specified or directed.
3.2.3 In no case will under cutting excavation faces for extended footings be permitted. Not less than twelve (12) inches clearance shall be provided between excavation faces and brick or block masonry exterior wall surfaces which are to be plastered.
11.13 02218-3 SECTION 02218
EXCAVATION
3.2.4 Subgrade for all concrete structures shall be undisturbed original earth, thoroughly compacted where noted on drawings. Where excavation below subgrade is ordered, it shall be a thoroughly compacted and consolidated lining, special lining or special backfill as directed and as specified in Section 02224. It shall be sufficiently stable to remain firm and intact during the surfacing of subgrade, laying reinforcing steel and placing concrete thereon.
3.2.5 Where necessary, a layer of Class "D" concrete of sufficient strength and thickness to withstand subsequent construction operations shall be installed below the specified subgrade elevation and the structural concrete deposited thereon. Subject to the approval of the Engineer, lining or special lining may be used for subsoil reinforcement if satisfactory results can be obtained thereby. Such material shall be applied in thin layers, each layer being entirely embedded in the subsoil by thorough tamping. All excess soil shall be removed to compensate for the displacement of the gravel or crushed stone and the finished elevation of any subsoil reinforced in this manner shall not be above the specified subgrade.
3.3 BACKFILLING AROUND STRUCTURES:
3.3.1 Backfilling around structures shall not be commenced until all lumber, refuse, rubbish and other similar materials are removed from the excavated area. Backfill around structures may be placed by machine, provided the work shall be done carefully to prevent damage to the structure. In no case shall backfill materials be allowed to fall directly on a structure, until at least twelve (12) inches of hand-placed material has been placed thereon and compacted.
3.3.2 Backfill around structures shall be deposited in horizontal layers not more than eight (8) inches in thickness and shall be thoroughly compacted. Compaction shall be by a vibrating tamper or other approved method and shall be to a minimum dry density of ninety-five (95) percent of the maximum dry weight density in pounds per cubic foot as determined by the AASHTO Standard Density Test or the Modified Proctor Compaction Test (ASTM D1557).
3.3.3 Backfilling shall be done immediately after work has been inspected and approved. No frozen material shall be used, nor shall backfilling be placed on or against frozen earth, debris or other deleterious matter not conducive to proper compaction. Backfill within building lines, under concrete slabs and aprons shall be granular fill as specified in Section 02222.
3.3.4 Backfilling against free standing walls shall be made against both sides at the same time. If backfill is required on one side only, the wall shall be adequately braced on the opposite side until properly cured to full strength.
11.13 02218-4 SECTION 02218
EXCAVATION
3.3.5 Contractor shall take every necessary precaution during compaction of fill adjacent to foundations, walls, etc., that such items are not displaced from their proper location or damaged by compacting equipment. In the event damage or displacement occurs during or resulting from compaction of fill as specified above, the Contractor shall be responsible for correcting the same, to approval of the Engineer and at no expense to the Owner.
3.4 TRENCHING:
3.4.1 The alignment, depth and pipe subgrades of all pipe trenches shall be determined by overhead grade lines parallel to the pipe invert, or other grade control devices, installed and maintained by the Contractor.
3.4.2 Under ordinary conditions, excavation shall be by open cut from the ground surface. Where the depth of trench and soil conditions permit, tunneling may be required beneath crosswalks, curbs, gutters, pavements, concrete driveways, railroad tracks and other surface structures. No additional compensation will be allowed for such tunneling over the price bid for open cut excavation of equivalent depths below the ground surface unless such tunnel excavation is specifically provided for in unit or lump sum price items.
3.4.3 Trenches shall not be opened for more than three hundred (300) feet in advance of the completed pipe or sewer nor left unfilled for more than one hundred (100) feet in the rear thereof without consent of the Engineer. Excavation of the trench shall be fully completed at least twenty (20) feet in advance of the pipe laying or construction of the invert unless specifically permitted otherwise.
3.4.4 Width and Depth of Trenches:
3.4.4.1 The trenches in which pipelines are to be constructed, shall be excavated in all cases in such manner and to such depths and widths as will give suitable room for the pipelines which the trenches are to contain, for sheeting, pumping, dewatering, well-pointing and draining of water, and for removing the material not suitable for pipe subgrade.
3.4.4.2 Trenches for pipes shall be not less than six (6) inches wider than the hubs of the pipe in the clear on each side, measured over the hubs of the pipe. Width of trenches, measured at a point twelve (12) inches above the top of the pipe shall not exceed twelve (12) inches on each side. Width of trenches greater than specified above will be permitted in the vicinity of joints for welded steel pipe where access for the welding of joints is required.
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3.4.4.3 Where, as required by loading conditions, the width of the lower portion of the trench, measured at twelve (12) inches above top of pipe, exceeds the maximum for the size of pipe, additional concrete cradle or concrete encasement shall be installed by the Contractor at his own expense.
3.4.4.4 Ledge rock, shale, boulders and large stones shall be removed to provide minimum bottom and side clearances, for the size of pipe being laid in each case, as follows:
Minimum Clearance Minimum Clearance Size of Pipe Below Pipe At Sides (Inches) (Inches) (Inches)
12 or smaller 4 6
15, 18, and 21 5 6
24 to 36 7 6
Over 36 9 7
Where concrete embedment or cradle is to be placed, it shall be placed directly on the rock, and the bottom clearance shall be adjusted as directed by the Engineer.
3.5 EARTH SUBGRADE PREPARATION FOR PIPES:
3.5.1 Unless otherwise permitted by the Engineer, the trench shall have a flat bottom conforming to the grade to which the pipe is to be laid.
3.5.2 Except where concrete cradle or encasement is required below the specified pipe subgrade, mechanical excavation of trenches for pipe shall not extend lower than one (1) inch above the finished pipe subgrade elevation at any point. The remainder of the trench excavation shall be made with hand tools.
3.5.3 Pipe subgrade preparation shall be performed immediately prior to installing the pipe in the trench. The trench bottom shall be accurately graded by means of hand tools in such a manner that a uniform and continuous bearing and support on solid and undisturbed ground is provided for each pipe for its entire length or between bell holes.
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3.5.4 All trenches shall be so graded that the spigot end of the pipe will be accurately centered in the adjacent pipe bell when laid, without raising the pipe off the trench bottom. Regrading of a trench bottom which is too high will be permitted. Correction of a subgrade that is too low shall be done only by placing and compacting lining over the entire width of the trench and regrading.
3.5.5 The trench bottom shall be accurately graded and ready for the installation of the pipe thereon prior to excavating bell holes if and where required.
3.5.6 Each bell hole shall be excavated immediately prior to laying the pipe therefor. Bell holes shall have a length, measured at the elevation of the pipe subgrade, not in excess of nine (9) inches and shall be of sufficient size so that no part of the pipe bell will be in contact with the trench bottom or granular fill thereon.
3.6 EXCAVATION FOR CONCRETE CRADLE OR ENCASEMENT:
3.6.1 Where concrete cradle or encasement is required, the trench subgrade elevation will be determined by the required concrete section in each case. Unless otherwise authorized by the Engineer, concrete cradle or encasement shall extend across the full width of the trench as excavated, and the concrete therein shall be poured directly against vertical trench banks. In the case of concrete cradle or encasement of pipe in a sheeted trench, the concrete may be poured directly against sheeting which is to be left in place in the trench, as specified.
3.7 PIPE EMBEDMENT:
3.7.1 All pipe shall be protected from lateral displacement and possible damage resulting from superimposed backfill loads, impact or unbalanced loading during backfilling operations by being adequately embedded in suitable pipe embedment material. Except where loading or subsoil conditions require the use of concrete cradle or encasement, all pipe embedment shall be placed so as to insure adequate lateral and vertical stability of the installed pipe during pipe jointing and embedment operations. A sufficient amount of the specified pipe embedment material to hold the pipe in rigid alignment shall be uniformly deposited and thoroughly compacted on each side, and back of the bell, of each pipe laid.
3.7.2 Pipe embedment materials placed at any point below an elevation six (6) inches above the top of pipe or sewer, shall be deposited and compacted in layers not to exceed four (4) inches in uncompacted depth, and such deposition and compactions shall be done simultaneously and uniformly on both sides of the pipe. Compaction shall be by vibrating tamper or other approved
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method and shall be to a minimum dry density of ninety-five (95) percent of the maximum dry weight density in pounds per cubic foot as determined by the Modified Proctor Compaction Test. All such materials shall be placed in the trench with hand tools in such a manner that they will be scattered alongside the pipe and not dropped into the trench in compact masses.
3.7.3 Concrete cradle and encasement of the class specified shall be installed where and as shown on the Plans or ordered by the Engineer. Before concrete cradle or encasement is placed, the pipe shall be braced in all directions to prevent movement or flotation.
3.8 BACKFILL ABOVE PIPE EMBEDMENT:
3.8.1 The portion of pipe trenches between the top of the pipe embedment (see paragraph 3.7) and the upper limit of backfill shall be refilled with suitable materials.
3.8.2 Where trenches are within the ditch-to-ditch or curb-to-curb limits of any street, road, driveway or other recognized traveled vehicular way, or within other limits that may be specifically shown or specified for this purpose, the backfill materials shall be deposited in the trench in horizontal layers not more than eight (8) inches in thickness, and each layer shall be compacted by vibrating tamper or other approved method and shall be to a minimum dry density of ninety-five (95) percent of the maximum dry weight density in pounds per cubic foot as determined by the Modified Proctor Compaction Test (ASTM D1557).
3.8.3 Where trenches are outside the ditch-to-ditch or curb-to-curb limits of any street, road, driveway or other recognized traveled vehicular way, and outside of other limits that may be specifically shown or specified as areas in which mechanical compaction in layers is to be performed, the backfill material may be deposited in the trench by mechanical means for the full depth of the trench between the top of pipe embedment and ground surface with no special compaction. In such case the backfill materials shall be mounded over the trench to an elevation slightly above desired finished grade to allow for settlement and compaction by natural means, and the Contractor shall return to the area during his clean-up operations to remove any excess materials remaining above finished grade or add sufficient additional backfill to bring the completed work to grade. If a hazard should be created by such excess materials, or by settlement below finished grade, prior to the performance of clean-up operations, the Contractor shall remove such excess, or add additional backfill, at the time the hazard is created or when directed.
3.8.4 Any additional material added during clean-up operations, or at any other time to prevent or remove a hazard, shall be placed in horizontal layers not more than eight (8) inches in thickness, with each layer adequately compacted by mechanical means, by the Contractor at his own expense.
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3.9 REMOVAL OF WATER:
3.9.1 The Contractor shall at all times during construction provide and maintain proper and satisfactory means and devices for the removal of all water entering the excavations, and shall remove all such water as fast as it may collect, in such manner as shall not interfere with the prosecution of the work or the proper placing of pipe, masonry, concrete, structures, or other work.
3.9.2 Removal of water includes the construction and removal of cofferdams, sheeting and bracing, the furnishing of materials, equipment and labor necessary therefore, the excavation and maintenance of ditches and sluice-ways and the furnishing and operation of pumps, wellpoints, and appliances needed to maintain thorough drainage of the work in a satisfactory manner.
3.9.3 Water shall not be allowed to rise over or come in contact with any masonry, concrete or mortar, until at least twenty-four (24) hours after placement, and no stream of water shall be allowed to flow over such work until such time as the Engineer may permit.
3.9.4 Unless otherwise specified, all excavations which extend down to below the ground water elevation at the sites of structures shall be dewatered by lowering and maintaining the ground water beneath such excavations at an elevation not less than that specified herein at all times when work thereon is in progress, during subgrade preparation and the placing of the structures or pipe thereon.
3.9.5 Where an upward pressure or flow of water in combination with a fine-grained subsurface material causes a quick condition, the Contractor shall install wellpoints to stabilize the subgrade. Where wellpoints are used, the ground water table shall be continuously (day and night) maintained to an elevation of not less than twenty-four (24) inches below the excavation and when subgrade is reached the ground water shall be maintained not less than twenty-four (24) inches below the subgrade. Unless otherwise permitted by the Engineer, the ground water shall be maintained not less than twenty-four (24) inches below the subgrade until completion of the backfilling to an elevation at least twelve (12) inches above natural ground water level. Wellpoint headers, points, and other pertinent equipment shall not be placed within the limits of the excavation in such a manner or location as to interfere with the laying of pipe or trenching operations or with the excavation for and construction of other structures.
3.9.6 In areas where ground water enters the excavation but does not cause a quick condition, the ground water may be removed by any practical method which does not damage the subgrade, cause the same to become unstable or interferes with construction operations.
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3.9.7 The ground water control requirements specified for wellpointing operations apply to other dewatering methods.
3.9.8 Suitable stand-by pumping equipment shall be provided to insure the maintenance of the specified lowering of the water table.
3.9.9 Water pumped or drained from excavations, or any sewers, drains, or water courses encountered in the work, shall be disposed of in a suitable and environmental manner without injury to adjacent property, the work under construction, or to pavements, roads, and drives. No water shall be discharged to sanitary sewers. Sanitary sewage shall be pumped to sanitary sewers or shall be disposed of by an approved method.
3.9.10 Any damage caused by improper handling of water shall be repaired by the Contractor at his own expense.
3.10 SHEETING & BRACING:
3.10.1 The Contractor shall furnish, place and maintain such sheeting, bracing and shoring as may be required to support the sides and ends of excavations in such manner as to prevent any movement which could, in any way, injure the pipe, sewers, masonry, or other work; diminish the width necessary; otherwise damage or delay the work; or endanger existing structures, pipes or pavements; cause the excavation limits to exceed the right-of-way limits; or to occasion a hazard to persons engaged on the project or to the general public.
3.10.2 In no case will bracing be permitted against pipes or structures in trenches or other excavations.
3.10.3 The Contractor shall be solely responsible for the safety and adequacy of all sheeting and bracing. He shall make good any damage resulting from failure of supports with no additional cost to Owner.
3.10.4 Removal of Sheeting & Bracing:
3.10.4.1 In general, all sheeting and bracing, whether of steel, timber or other material, used to support the sides of trenches or other open excavations, shall be withdrawn as the trenches or other open excavations are being refilled. That portion of the sheeting extending below the top of a pipe or sewer shall be withdrawn, unless directed, before more than six (6) inches of earth is placed above the top of the pipe or sewer and before any bracing is removed. The voids left by the sheeting shall be carefully refilled with selected material and rammed tight with tools especially adapted for the purpose, or otherwise as may be approved.
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3.10.4.2 The Engineer may order the Contractor to delay the removal of sheeting and bracing, if in his judgement the installed work has not attained the necessary strength to permit placing of backfill.
3.10.5 Sheeting & Bracing Left In Place:
3.10.5.1 If, to serve any purpose of his own, the Contractor files a written request for permission to leave sheeting or bracing in the trench or excavation, the Engineer may grant such permission, in writing, on condition that the cost of such sheeting and bracing be assumed and paid by the Contractor.
3.10.5.2 The Contractor shall leave in place all sheeting, shoring and bracing which are shown on the Drawings or specified to be left in place or which the Engineer may order, in writing, to be left in place. All shoring, sheeting, and bracing shown or ordered to be left in place will be paid for under the appropriate item of the Contract. No payment allowance will be made for wasted ends or for portions above the proposed cut-off level which are driven down instead of cut-off.
3.10.5.3 In case sheeting is left in place, it shall be cut off or driven down as directed so that no portion of the same shall remain within twelve (12) inches of the finished street or ground surface.
3.10.5.4 All timber sheeting and bracing to be left in place and paid for under an item of the Contract shall be new, sound and straight, free from cracks, shakes and large or loose knots, and shall otherwise conform with National Design Specifications for Stress Grade Lumber for lumber of a minimum fiber stress of 1,200 pounds per square inch.
3.10.5.5 Steel sheeting and bracing left in place and paid for under an item of the Contract shall be new and shall conform with ASTM Des: A7, with a minimum thickness of 3/8-inch.
3.10.5.6 Sheeting and bracing left in place and paid for under an item of the Contract shall be driven as the excavation progresses and in such manner as to maintain pressure against the original ground at all times. The sheeting shall be driven vertical with the edges tight together, and all bracing shall be of such design and strength as to maintain the sheeting in its proper position.
3.11 STORAGE OF MATERIAL:
3.11.1 Any sod cut during excavation shall be removed and stored during construction so as to preserve the grass growth, and shall be replaced in position upon completion of the work.
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3.11.2 Topsoil suitable for final grading shall be removed and stored on the Site separately from other excavated material, and shall be replaced in position upon completion of the work.
3.11.3 All excavation materials shall be stored in locations so as not to endanger the work, and so that easy access may be had at all times to all parts of the excavation. Stored materials shall be kept neatly piled and trimmed, so as to cause as little inconvenience as possible to public travel or to adjoining property holders. All stockpiled fill material shall be stored only in those fill areas as approved by the Engineer and the New York State Department of Environmental Conservation.
3.11.4 All excavated materials shall be kept clear of all sidewalks, driveway entrances, street crossings, and any other points that may inconvenience the public. Special precautions must be taken to permit access at all times to fire hydrants, fire alarm boxes, police and fire department driveways, and other points of public convenience.
3.11.5 Where traffic is to be maintained, at least one-half (1/2) of the street width must be kept open at all times. Approved types of bridging across trenches shall be constructed and maintained where necessary. Where conditions do not permit storage of materials, the material excavated from the first one hundred (100) feet of any opening, or from such additional length as may be required, shall be removed from the street by the Contractor, at his own cost and expense, as soon as excavated. The material subsequently excavated shall be used to refill the trench where the facility has been built, provided it be of suitable character.
3.11.6 If more material is excavated from any trench, excavation, or pit than can be refilled over the completed work or stored on the street, leaving space for traffic as herein provided, or within the limits of the right-of-way, the excess material shall be spoiled at locations selected and obtained by the Contractor. A copy of the signed agreement between the property owner and Contractor granting permission to deposit spoil shall be given to the Engineer prior to placement. When the facility is complete, the Contractor shall, at his own cost and expense, bring back adequate amounts of satisfactory excavated materials as may be required to properly refill the trenches, excavations, or pits. If directed by the Engineer, the Contractor shall refill such trenches, excavations, or pits with special backfill or other suitable materials, and excess excavated materials shall be disposed of as spoil.
3.12 DRAINAGE:
3.12.1 All material deposited in roadway ditches or other water courses crossed by the line of trench or near a structure shall be removed immediately after backfilling is completed and the section grades and contours of such ditches or water course restored to their original condition, in order that surface drainage will be obstructed no longer than necessary.
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3.12.2 Backfilling of trenches for pipes installed beneath or across roadways, driveways, walks and other traffic ways adjacent to drainage ditches and water courses shall not be done prior to the completion of backfilling to the original ground surface of the trench on the upstream side of such traffic-way in order to prevent the impounding of water at any point after the pipe has been laid, and all necessary bridges and other temporary structures required to maintain traffic across such unfilled trenches shall be constructed and maintained. All backfilling shall be done in such a manner that water will not accumulate in unfilled or partially filled trenches.
3.12.3 Where trenches are constructed in or across roadway ditches or other water courses, the backfill shall be protected from surface erosion by adequate and environmentally sound means. Where trenches cross such waterways; the backfill surface exposed on the bottom and slopes thereof shall be protected by means of stone or concrete riprap, at no additional cost to the Owner.
3.13 ADDITIONAL EXCAVATION:
3.13.1 In case the materials encountered at the locations and grades shown on the Plans or specified are not suitable, or in case it is found desirable or necessary to excavate additional materials to secure good support for the structure or pipeline, the excavation shall be carried to such additional limits as the Engineer may direct. The Contractor shall refill such additional excavated space with either lining, special lining, Class "D" or "E" concrete or other material, as the Engineer may direct. Additional excavation, lining, special backfill, concrete or other materials so ordered, will be paid for under the appropriate items of the Contract.
3.14 UNAUTHORIZED EXCAVATION:
3.14.1 Whenever excavations are carried beyond or below the lines and grades shown on the Plans, or as given or directed by the Engineer, all such excavated space shall be refilled with lining, special backfill, concrete or other materials as the Engineer may direct. Beneath structures, all such excavated space shall be refilled with Class "D" concrete. All refilling of unauthorized excavations shall be at the Contractor's own expense.
3.14.2 All material which slides, falls or caves into the established limits of excavations due to any cause whatsoever shall be removed and disposed of at the Contractor's own expense, and no extra compensation will be paid the Contractor for any materials ordered for refilling the void areas left by the slide, fall or cave-in.
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3.15 DISPOSAL OF MATERIALS:
3.15.1 All spoil shall be transported and placed on the Site of the work at the locations and to the elevations and grades shown on the Plans, or if spoil areas are not shown, all spoil materials shall be disposed off the Site at appropriate locations selected and obtained by the Contractor and approved by the Engineer and the New York State Department of Environmental Conservation. No environmental sensitive areas shall be used for spoil areas. A copy of the signed agreement between the property owner and the Contractor granting permission to deposit spoil shall be given to the Engineer prior to placement.
3.15.2 The surface of all spoil placed on the Site shall be graded and dressed, and no unsightly mounds or heaps shall be left on completion of the work.
3.16 UNFINISHED WORK:
3.16.1 When for any reason the work is left unfinished, all trenches and excavations shall be filled and all roadways and sidewalks left unobstructed with their surfaces in a safe and satisfactory condition.
3.17 HAULING MATERIAL ON STREETS:
3.17.1 When it is necessary to haul material over the streets or pavements, the Contractor shall provide suitable tight vehicles so as to prevent deposits on the streets or pavements. In all cases where any materials are dropped from the vehicles, the Contractor shall clean up the same at least daily or as often as directed and keep the crosswalks, streets and pavements clean and free from dirt, mud, stone and other hauled material.
3.18 TEST PITS:
3.18.1 For the purpose of locating underground obstructions, the Contractor shall make such excavations in advance of the work as directed. Payment for the excavations of test pits will be made under an appropriate item of the Contract.
3.19 RESTORATION OF SURFACES:
3.19.1 The various types of street surface, gutters and culverts, disturbed, damaged or destroyed during the performance of the work under the Contractor, shall be restored and maintained as specified herein and as shown and directed.
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3.19.2 Restoration of Property:
3.19.2.1 The Contractor shall restore all pavement, driveways, sidewalks, gutters, culverts, trees, shrubs, lawns, landscaped areas and any other public or private property damaged as a result of work under this Contract. The quality of materials and workmanship used in the restoration shall produce a condition equal to or better than the condition before the work began. If conditions are inferior before restoration, they shall be superior after restoration.
3.19.2.2 Payment for restoration of property shall be included in the applicable excavation items unless specifically provided for in other unit or lump sum price items.
3.19.3 Time of Replacement:
3.19.3.1 In general, permanent restoration of street surfaces will not be permitted until one month's time has elapsed after trenches have been completely backfilled as specified. A greater length of time, but not more than nine (9) months, may be allowed to elapse before permanent restoration of street surfaces is undertaken, if, in the opinion of the Engineer such additional time is required for complete shrinkage and settlement of the backfill.
3.19.3.2 If the Contractor is permitted to replace pavement at any time by the Engineer, it shall not relieve the Contractor of responsibility to make repairs to damage caused by settlement for a period of one year or as elsewhere specified.
3.19.4 Schedule of Operations:
3.19.4.1 A schedule of replacement operations shall be worked out by the Contractor, and approval of the Engineer shall be obtained. The program shall be adhered to unless otherwise approved by the Engineer.
3.19.5 Temporary Resurfacing & Repaving:
3.19.5.1 Immediately upon completion of refilling of the trench or excavation, the Contractor shall place a temporary pavement over all disturbed areas of the streets, driveways, alleys and other traveled places where the original surface has been disturbed by his operations. The temporary repavement shall be of a character satisfactory in all respects and safe for public travel.
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3.19.5.2 The temporary resurfacing shall consist of a minimum of six inches (6") of well- graded broken stone with such additional depth as is necessary to withstand the traffic to which it is subjected. Where concrete pavements are removed, the broken stone shall be surfaced with "cold patch". The surface of the temporary repaving shall conform to the street grades. Mounding up of the material over the trench and covering the same with loose broken stone will not be considered as compliance with the above requirements.
3.19.5.3 For dust prevention, the Contractor shall treat all surfaces, not covered with cold patch, as approved by the Engineer. Use of calcium chloride and/or petroleum products for dust control is prohibited.
3.19.5.4 The temporary repavement shall be placed and maintained by the Contractor in a safe and satisfactory condition until such time as the permanent repaving is completed. The Contractor shall immediately remove and restore to a satisfactory condition any and all such resurfacing and repavements as shall become unsatisfactory and not in accordance with the terms and intent of the Specifications.
3.19.6 Preparation for Permanent Replacement:
3.19.6.1 After due notice and within the time specified, the temporary broken stone or gravel pavement shall be prepared as the base to receive the permanent pavement. It shall be brought to the required grade and cross section and thoroughly compacted before placing the permanent pavement. Service boxes, manhole frames and covers, and similar structures, within the area of pavement to be replaced and not conforming to the new work, shall be set to established grade by the Contractor at his expense, unless a specific item is included in the Contract.
3.19.7 Permanent Repaving:
3.19.7.1 The permanent and final repaving of all streets, driveways and similar surfaces where pavement has been removed, disturbed, settled or damaged by or on account of the work of the Contract shall be repaired and replaced by the Contractor, by a new and similar pavement at such time as directed. The top surface shall conform with the grade of existing adjacent pavement, and the entire replacement shall meet the current specifications of the local community for the particular types of pavement.
3.19.7.2 Concrete pavement and concrete base beneath asphalt, brick and other pavement surfacings supported by a concrete base, shall be replaced with Class "B" concrete.
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3.19.7.3 Undamaged brick removed from brick pavement laid with sand or a bituminous filler may be reused in the pavement replacement. All broken and otherwise damaged brick, even though such brick were broken prior to removal, and all brick from grout filled pavement, shall be replaced with new brick of equal or better quality by and at the expense of the Contractor.
3.19.7.4 Where specified or approved by the Engineer, in writing, brick or block surfacing may be replaced by placing Class "B" concrete even with the adjacent wearing surface.
3.19.7.5 All pavement other than brick and concrete, and all gravel, crushed stone, and other types of roadway surfacings shall be replaced with new materials except where, in the opinion of the Engineer, materials salvaged from stone or gravel roadways have been removed, handled, and stored in such a manner that their original quality has been maintained, in which case such salvaged materials may be used to the extent available in the lower portion of the roadway surfacing after proper screening to remove dust and other excess fine material.
3.19.7.6 All such roadway surfacings shall be replaced to their original thickness at all points and such replacement shall in all cases conform in type, kind, and quality to the original when built. Where specifications covering the original construction are available, such specifications will apply to the replacement work. If not, the work shall be done in conformity with the State Department of Transportation Standard which conforms the closest to the type of surfacing being replaced, as determined by the Engineer.
3.19.8 Concrete Walks:
3.19.8.1 Concrete walks removed in connection with, or damaged as a result of, construction operations under the Contract shall be replaced with new construction; such walks shall be constructed of Class "B" concrete on a thoroughly compacted subgrade, shall have a vertical thickness of not less than four (4) inches (or thickness of the replaced walk where greater than four (4) inches), shall be constructed with vertical construction joints spaced not more than twenty-five (25) feet apart, shall be provided with expansion joints spaced not to exceed fifty (50) feet apart, and shall be sloped for drainage at right angles to the longitudinal center line in the amount of approximately 1/8-inch per foot of walk width.
3.19.8.2 Walks shall be float finished, edged with an edging tool, and grooved at construction joints and at intermediate intervals not in excess of the width of the walk. The length of blocks formed by grooving tool and distances between construction and expansion joints shall be uniform throughout the length of the walk in any one location. All walks shall be cured as specified for concrete slabs in the Section headed "Cast-In-Place Concrete".
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3.19.9 Curbs, Gutters & Culverts:
3.19.9.1 The Contractor shall, at his own cost and expense, permanently repair and relay all curbs, gutters, roadway and driveway culverts, where the same have been broken, injured or disturbed by the Contractor, his agents or employees, in executing any of the work covered by the Contract or by or on account of said work. He shall restore the same in a manner, to a condition and with material, either new or old as required, similar and equal to that existing before such excavations were made.
3.19.10 Maintenance & Surfaces:
3.19.10.1 The pavements, sidewalks, curbs, driveways, gutters, culverts, restored lawns, shrubs, trees, landscaped areas and any other public or private property shall be maintained in satisfactory condition during a period of one year from and after completion and acceptance of the Contract.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - EXCAVATION - GENERAL:
4.1.1 The quantity of Excavation - General for which payment will be made shall be the number of cubic yards actually removed, measured as the volume occupied by it (including rocks) before its removal; the maximum limits of such volumes shall not exceed those defined by the drawings, specified or ordered.
4.2 PAYMENT - EXCAVATION - GENERAL:
4.2.1 For Excavation - General, not included in other unit or lump sum price items, will be made at the applicable price stated in the Bid and shall include the cost of all the several detailed operations incidental to the excavation. No additional payment will be made for excavation of rock, boulders, masonry or concrete encountered in the work. No payment will be made for material not excavated between the actual excavation and the maximum payment limits, if shown.
4.3 MEASUREMENT - EXCAVATION BELOW SUBGRADE:
4.3.1 The quantity of Excavation Below Subgrade, for which payment will be made, shall be the number of cubic yards (including rock) removed in accordance with the drawings, specified and/or ordered.
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4.4 PAYMENT - EXCAVATION BELOW SUBGRADE:
4.4.1 For Excavation Below Subgrade, not included in other unit or lump sum price items, will be made at the applicable price stated in the Bid and shall include and cover all costs incidental to Excavation Below Subgrade when ordered. No additional payment will be made for excavation of rock, boulders, masonry, or concrete encountered in the work.
4.5 MEASUREMENT - EXCAVATION - TRENCHING:
4.5.1 The quantity for which payment will be made for Excavation - Trenching shall be the number of lineal feet, horizontal measurement, on the center line of the trench. The depth shall be measured on the center line of the trench from the invert or grade line to the original ground surface. Excavation - Trenching will be measured continuously through standard drop manholes, and no deduction will be made therefor. For other structures, deduction shall be made for length of trench occupied by the structures.
4.6 PAYMENT - EXCAVATION - TRENCHING:
4.6.1 For Excavation - Trenching, not included in other unit or lump sum price items, payment for Excavation - Trenching will be made at the price bid per lineal foot of Trenching for the various depths stated and shall include and cover all costs incidental to the trenching. No additional payment will be made for excavation of rock, boulders, masonry, or concrete encountered in the work. If so stated in the Additional Instructions, a percentage of the funds or unit amount to be retained under Excavation - Trenching will be withheld until all surface restoration is completed.
4.7 MEASUREMENT - EXCAVATION FOR STRUCTURES:
4.7.1 The quantity of Excavation for Structures for which payment will be made shall be the number of cubic yards actually removed, measured as the volume occupied by it (including rock) before its removal unless otherwise specified; the maximum limits of such volumes shall not exceed those defined upon drawings, specified and/or ordered.
4.8 PAYMENT - EXCAVATION FOR STRUCTURES:
4.8.1 For Excavation For Structures, not included in other unit or lump sum price items, payment for Excavation For Structures will be made at the applicable unit price stated in the Bid and shall include and cover the cost of all the several detailed operations incidental to the excavation. No additional payment will be made for excavation of rock, boulders, masonry, or concrete encountered in the work. No payment shall be made for material not excavated between the actual excavation and the maximum payment limits if shown.
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4.9 MEASUREMENT AND PAYMENT - EXCAVATION - TEST PITS:
4.9.1 Measurement and Payment for Excavation - Test Pits, not included in other unit or lump sum price items will be made in accordance with the following schedule:
4.9.1.1 If a specific item for Excavation - Test Pits is included in the Bid, payment shall be made at the applicable unit price stated in the Bid. Measurement of quantity shall be the actual number of cubic yards removed and replaced, measured as the volume occupied by it before its removal in accordance with the limits ordered by the Engineer.
4.9.1.2 If no specific item for Excavation - Test Pits is included in the Bid, Excavation - Test Pits shall be measured and paid for in accordance with the Section entitled - Measurement & Payment, Excavation - General.
4.9.1.3 If neither of the above two items are included in the Bid, Excavation - Test Pits shall be measured and paid for in accordance with the Section entitled - Measurement & Payment Excavation - Trenching.
4.10 MEASUREMENT - EXCAVATION - ROCK:
4.10.1 Unless a specific item of Excavation - Rock is included in the Bid, no additional payment will be made for Rock encountered in the work.
4.10.2 If a specific item of Excavation - Rock is included in the Bid, measurement for payment shall be the actual volume of Rock excavated, measured within the limits specified or directed by the Engineer.
4.11 PAYMENT - EXCAVATION - ROCK:
4.11.1 For Excavation - Rock, not included in other unit or lump sum price items, payment for Excavation - Rock will be made at the price stated in the Bid, and shall include and cover all costs incidental to Excavation - Rock.
END OF SECTION
11.13 02218-20 SECTION 02222
GRANULAR FILL
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Granular Fill, as shown on the Plans, as specified, and/or directed.
PART 2 - PRODUCTS
2.1 GRANULAR FILL:
2.1.1 For pipe and structure backfill, the Granular Fill shall consist of crushed stone, well graded from coarse to fine, conforming to New York State Department of Transportation Standard Specifications Item 733-0403.
2.1.2 Granular fill for road construction shall be as indicated on the Contract Drawings.
2.1.3 The Contractor shall submit to the Engineer for approval a certified sieve analysis and Modified Proctor Compaction Test for each source or type of granular fill, at no additional cost to the Owner.
PART 3 - EXECUTION
3.1 PLACING:
3.1.1 The Granular Fill shall be spread in horizontal layers so that the maximum thickness of any layer after compaction shall not exceed eight (8) inches. Compaction shall be by traveling vibrators or other approved method and shall be to a minimum dry density of ninety percent (90%) of the maximum dry density as determined by the Modified Proctor Test, ASTM D1557 unless otherwise specified. Each layer shall be thoroughly compacted before placement of overlying layers.
3.2 COMPACTION TEST:
3.2.1 The Contractor shall employ an approved commercial testing laboratory at his own expense to conduct the compaction tests.
6.19 02222-1 394.107.001 SECTION 02222
GRANULAR FILL
3.2.2 Each layer shall be tested, and approved by the Engineer before succeeding layers are placed. A minimum of one field density test shall be made each day and/or for each fifty (50) cubic yards of material placed and/or as shown or specified in the drawings.
3.2.3 The following reports in quadruplicate shall be submitted directly to the Engineer:
a. Report and Certification of Gradation.
b. Field Density Reports.
3.2.4 Based on the reports of the testing laboratory and inspection, if the subgrade or fills which have been placed and compacted are below the specified density, the Engineer will ask for additional compaction and testing at the expense of the Contractor.
PART 4 – MEASUREMENT & PAYMENT
4.1 MEASUREMENT – GRANULAR FILL:
4.1.1 The quantity of Granular Fill allowed for payment shall be computed by using the product of the length, depth as directed, and the actual width, but not to exceed the Maximum Payment Width as shown on the Contract Drawings, less the volume occupied by the pipe or structure, if any.
4.2 PAYMENT – GRANULAR FILL:
4.2.1 For Granular Fill, not included in other unit or lump sum price items, payment for Granular Fill will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 02222-2 394.107.001 SECTION 02225
SELECT FILL MATERIALS
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Select Fill Materials as shown on the Plans, as specified, and/or directed.
1.1.2 Work under this Section shall include furnishing, transport, dumping, placement, and testing of Select Fill Materials in the areas and to the depths and grades shown on the engineering drawings and/or directed by the Engineer.
PART 2 - PRODUCTS
2.1 MATERIALS:
2.1.1 Select fill materials shall be of the types listed below:
Type (A) - Select Fill Type (B) - Select Fill Type (D) - Select Fill
2.1.1.1 Type (A) - Select fill shall consist of clean, sound, rounded stone, conforming to the gradation shown below:
% Passing By Weight Sieve
100 3.5" 50 - 100 2-1/2" 0 - 5 1/2" 0 - 3 #200
In addition, this material must be free of organic material and coatings, and possess a minimum permeability of 1.0 cm/sec at a relative density of 90 percent. Modifications to the intermediate sieve gradations may be submitted for review and approval.
2.1.1.2 Type (B) - Select fill shall consist of clean, sound, rounded stone, conforming to the gradation shown below:
6.19 02225-1 394.107.001 SECTION 02225
SELECT FILL MATERIALS
% Passing By Weight Sieve
100 2" 50 - 100 1-1/2" 0 - 5 1/2" 0 - 3 #200
In addition, this material must be free of organic material and coatings, and possess a minimum permeability of 1.0 cm/sec at a relative density of 90 percent. Modifications to the intermediate sieve gradations may be submitted for review and approval.
2.1.1.2 Type (D) - Select fill shall consist of clean, sound, medium to course sand conforming to the gradation shown below:
% Passing By Weight Sieve
100 1" 50 - 100 1/2" 0 - 3 #200
2.1.2 Special Considerations:
2.1.2.1 Material to be utilized for Types (A) and (B) select fill shall have a calcium carbonate content of less than 15% as determined by the methodology outlined in ASTM D3042. The test shall be conducted using the procedures outlined in ASTM D3042 using distilled vinegar in place of the specified 6M hydrochloric acid.
2.1.3 Submittals:
2.1.3.1 The Contractor shall submit to the Engineer for approval a certified sieve analysis, the minimum permeability, calcium carbonate content (Types (A) and (B)), the minimum and maximum relative densities as determined by an independent testing laboratory for each type of Select Fill Material, at no cost to the Owner. All tests will be performed in accordance with the methods outlined in this Section.
6.19 02225-2 394.107.001 SECTION 02225
SELECT FILL MATERIALS
PART 3 - EXECUTION
3.1 USAGE:
3.1.1 Type (A) - Select fill material will be used to construct the primary leachate collection layer, or as directed by the Engineer.
3.1.2 Type (B) - Select fill material will be used to construct the pipe embedment and cover for the primary and secondary leachate and groundwater suppression pipes, and the leachate storage tank leak detection pipe, or as directed by the Engineer.
3.1.3 Type (D) - Select fill material will be used for the leachate storage tank leak detection layer.
3.2 PLACEMENT:
3.2.1 Select fill materials shall be installed in accordance with Specification Section 02218, "Excavation", except as modified herein.
3.2.2 For all Select Fill Materials, the following preparation and inspection shall be conducted prior to placement:
a. Insure all placement procedures do not damage any underlying soil or geosynthetic layers. Equipment must access on approved temporary haul roads.
b. Verify stockpiled material to be used is approved for the particular layer.
c. Verify areas to be filled are properly compacted and all geosynthetics are in place.
d. Verify areas to be backfilled are free of debris, snow, ice or water and ground surfaces are not frozen.
e. Identify required lines, levels, contours and datums.
f. Proof roll existing subgrade as directed by the Engineer.
g. Multiple cover spreading points will not be allowed. One initial spreading location shall be established, and the work shall proceed from this location towards a free end of the geomembrane. Select fill material must be placed using vertical placement
6.19 02225-3 394.107.001 SECTION 02225
SELECT FILL MATERIALS
techniques. No horizontal pushing of the initial soil lift above the geomembrane will be allowed.
3.2.3 For Types (A) and (B) select fill material, the following specific placement procedures shall be followed:
a. Place select fill to contours and elevations shown on Contract Drawings. Use unfrozen materials.
b. Spread systematically, with low ground pressure equipment which exerts a ground pressure of no more than 4.5 psi pounds per square inch in a manner that will minimize movement of the underlying geotextile and geomembrane materials and potential for puncture of geotextile and geomembranes.
c. Spread select fill in loose lifts up to 24 inches thick and compact using the weight of the dozer and/or a smooth drum static roller to a minimum relative density of 50 percent. Hand tamp or vibrate as required in areas not accessible to heavy compaction equipment.
d. Where heavy compaction equipment cannot access, hand tamp or vibrate select fill in 6-inch lifts, and/or as directed by the Engineer.
e. Refer to Section 02596 for placement of select fill over HDPE Lining Materials.
3.3 FIELD TESTING AND QUALITY CONTROL:
3.3.1 In-place density will be visually approved by the Engineer for the select fill materials with field density tests performed as requested by the Engineer at the Contractor's expense.
3.3.2 The Contractor shall perform one grain size analysis (ASTM C136/ASTM C117) and one laboratory permeability test (ASTM D2434) for every 2,500 cubic yards of stockpiled material as it is being delivered to the site.
3.3.3 In addition to field density testing, the following laboratory testing will be performed at the Contractor's expense by an independent testing laboratory on samples of the select fill material. All samples of the select fill materials will be taken from in-place material in the Engineer’s presence and shall be evenly distributed across the cell area.
a. One grain size (ASTM C136/ASTM C117) analysis every 1,000 cubic yards of in- place material, or as directed by the Engineer.
6.19 02225-4 394.107.001 SECTION 02225
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b. One laboratory permeability test in accordance with ASTM D2434 per every 2,500 cubic yards of in-place material, or as directed by the Engineer. The sample location shall be approved by the Engineer and shall be representative of the in-place material.
c. One minimum/maximum relative density test in accordance with ASTM D4253 and ASTM 4254 for every 5,000 cubic yards of in-place material.
3.4 CRITERIA AND TOLERANCES:
3.4.1 Criteria and tolerances of the select fill material are as listed in Paragraph 2.1.
3.5 REMEDIATION OF FAILED TEST RESULTS:
3.5.1 If laboratory test results indicate that the in-place material fails to meet the required specifications, additional samples shall be taken in the field and tested in order to isolate the unacceptable area. Once the limits of unacceptable material have been defined, the Contractor shall remove the unacceptable material, replace it and retest the new material, at no additional cost to the Owner.
3.5.2 If unacceptable material is above a geomembrane, the unacceptable material will be removed to within 4 inches of the geomembrane and replaced. An additional 4 inches of material will be required to replace the unacceptable material that is left in place. Testing of the final layer will be performed on a sample representative of the actual completed lift.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - SELECT FILL MATERIALS:
4.1.1 For Select Fill Materials, not included in other payment items, the quantity allowed for payment shall be computed by using the product of the length, depth as directed and the actual width, but not to exceed the Maximum Payment Width as shown on the Contract Drawings, less the volume occupied by the pipe or structure, if any.
6.19 02225-5 394.107.001 SECTION 02225
SELECT FILL MATERIALS
4.2 PAYMENT - SELECT FILL MATERIALS:
4.2.1 For Select Fill Materials, not included in other unit or lump sum price items, payment for Select Fill Materials will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 02225-6 394.107.001 SECTION 02236
GEOSYNTHETIC CLAY LINING MATERIAL (GCL)
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for a reinforced, needle-punched, Geosynthetic Clay Lining Material (GCL), as shown on the Plans, as specified, and/or directed.
1.1.2 The GCL will be used in the primary liner composite system. The GCL will be bound by 12 inches of structural fill below and a textured 60 mil High Density Polyethylene (HDPE) geomembrane above.
1.2 PRE-QUALIFICATIONS:
1.2.1 GCL Manufacturer:
1.2.1.1 The Contractor shall submit to the Owner and the Engineer for approval the following qualification information regarding the GCL Manufacturer:
a. Corporate background and information.
b. Manufacturing capabilities including:
- daily production quantity available for this Contract - quality control procedures for manufacturing - list of material properties including certified test results, to which GCL samples are attached.
c. A list of at least ten completed facilities, totaling a minimum of 5,000,000 sq. ft, for which the Manufacturer has manufactured a GCL. For each facility, the following information will be provided:
- name and purpose of facility, its location and date of installation - name of Owner, Project Manager, Designer, and Installer (including addresses and phone numbers) - surface area of GCL manufactured - available information on the performance of the lining system and the facility.
2.19 02236-1 394.107.001 SECTION 02236
GEOSYNTHETIC CLAY LINING MATERIAL (GCL)
1.2.2 GCL Installer:
1.2.2.1 The Installer must be trained and qualified to install GCL material, and must be approved and/or licensed by the GCL Manufacturer.
1.2.2.2 The Contractor shall submit to the Engineer for approval the following written information, relative to the Installer:
a. Copy of Installer's letter of approval or license by the Manufacturer.
b. Corporate background and information.
c. Description of installation capabilities, including:
- information on equipment and personnel - average daily production anticipated - quality control procedures.
d. A list of at least three completed facilities, totaling a minimum of 1,000,000 sq. ft. for which the Installer has installed GCL of the type for this project. For each installation, the following information will be provided:
- name and purpose of facility, its location and date of installation - name of Owner, Designer, Manufacturer, and contact at the facility who can discuss the project (including addresses and phone numbers) - surface area of the installed GCL - available information on the performance of the lining system and the facility.
e. Resume of crew supervisor(s).
1.2.3 The Contractor shall submit detailed shop drawings. Shop drawings shall contain all necessary panel layouts, details, dimensions, penetration fabrications, etc., sufficient to assure that fabrication shall meet the intended use and will conform to the geometry of its intended application.
1.2.4 The Contractor shall submit a draft copy of the warranty to be provided upon completion of the project. The warranty shall meet the requirements of Article 3.2.3 of this Specification.
2.19 02236-2 394.107.001 SECTION 02236
GEOSYNTHETIC CLAY LINING MATERIAL (GCL)
1.2.5 Documentation shall be submitted for long-term creep testing of the needlepunched GCL (or for the family of needlepunched GCL products related to the needlepunched GCL) under hydrated conditions with a constant strain of 250 psf (12kPa) under a normal load of 500 psf (24kPa). The total shear displacement after 10,000 hours of creep testing shall be less than 25% of the displacement at the peak shear strength for hydrated direct shear testing under a normal load of 500 psf (24kPa) and a shear rate of 0.04 in/min.
1.2.6 All manufacturer’s quality control data as stated in articles 2.3.1.2 and 2.3.3.
PART 2 - PRODUCTS
2.1 MATERIALS:
2.1.1 The GCL shall be prefabricated in a manufacturing facility with a uniform layer of natural sodium bentonite (bentonite). The layer of bentonite shall be encapsulated between one woven and one nonwoven geotextile. The GCL shall be a reinforced GCL, with the upper and lower geotextiles needle-punched together. Acceptable reinforced GCL products include Bentomat ST, as manufactured by Colloid Environmental Technologies Company (CETCO), or an approved equal.
2.1.2 Required GCL Material Specifications:
2.1.2.1 The primary component of the GCL is high quality sodium bentonite (montmorillonite). The bentonite used to manufacture the GCL must demonstrate the following criteria:
a. Natural Sodium Bentonite - at least 90% montmorillonite content by weight when tested with x-ray defraction
b. Mass Per Unit Area at 0% Moisture - 0.75 lb/ft2 (ASTM D5993)
c. Swell Index - 24 ml/2 g minimum (ASTM D5890)
d. Fluid Loss – 18 ml maximum (ASTM D5891)
2.1.2.2 The upper and lower geotextile materials shall protect the bentonite but shall be sufficiently porous to allow bentonite flow-through the geotextile upon hydration with a minimum loading of 5 psi. This will insure proper intimate contact with the 60 mil HDPE geomembrane and proper bentonite-to-bentonite seals at the seams.
2.19 02236-3 394.107.001 SECTION 02236
GEOSYNTHETIC CLAY LINING MATERIAL (GCL)
2.1.3 Finished GCL Product:
2.1.3.1 The minimum dimensions of each GCL panel shall be 12 feet wide by 100 feet long.
2.1.3.2 The GCL material shall meet the minimum Specification values listed below:
PROPERTY TEST METHOD REQUIRED VALUES
Grab Strength ASTM D4632 90 lbs (MD)
Peel Strength ASTM D4632 15 lbs (MD)
Permeability (1) ASTM D5084 5 x 10-9 cm/sec (max.)
Hydrated Internal Shear ASTM D5321 500 psf (Typ.) Strength(2)
(1) Measure with a minimum confining stress of 80 psi, 77 psi head pressure, and 75 psi tail pressure. (2) Peak value measured at 200 psf normal stress.
2.1.3.3 The bentonite content of any random sample from each roll shall have a MARV value of 0.75 lb/sq ft calculated at a 0% moisture content, exclusive of weight of adhesives.
2.1.3.4 Documentation must be provided by the manufacturer ensuring that each roll of GCL has been inspected for the presence of broken needles using an in-line metal detector.
2.1.4 Labeling GCL Rolls:
2.1.4.1 Labels on each roll will identify:
- The manufacturer - The length and width of the roll panel - The weight of the roll - Product identification - Lot number - Roll panel number - Label shall be attached to the roll.
2.19 02236-4 394.107.001 SECTION 02236
GEOSYNTHETIC CLAY LINING MATERIAL (GCL)
2.2 DELIVERY, HANDLING AND STORAGE:
2.2.1 The finished GCL product shall be wrapped and adequately secured with a black polyethylene protective cover in order to provide protection from ultra violet degradation.
2.2.2 All delivered GCL rolls shall be visually inspected and approved by the Engineer prior to installation. Defects or damage from shipping and handling shall be grounds for rejection at the discretion of the Engineer.
2.2.3 The rolls of bentonite liner shall be stored in their original unopened wrapped cover in a clean, dry area. The material shall be stored off the ground on pallets or other suitable techniques and shall be covered with a heavy protective tarpaulin or stored beneath a roof. Care shall be used to keep the bentonite rolls clean, dry and free from debris prior to installation.
2.2.4 The Owner will provide adequate storage space at the site within the limits of work as shown on the Contract Drawings.
2.2.5 As each roll is moved from the storage area the labels shall be removed by the Installer and submitted to the Engineer for storage in the permanent project file.
2.2.6 The Contractor shall notify the Owner of the anticipated delivery time.
2.3 CONFORMANCE TESTING: (Manufacturer's Minimum Quality Control Testing)
2.3.1 Raw Materials:
2.3.1.1 The bentonite used to fabricate the GCL shall be sampled and tested upon arrival at the manufacturing plant. A minimum of 1 sample shall be taken from each 50 tons of bentonite delivered. Raw material having test results outside the allowable criteria (paragraph 2.1.2.1), shall be rejected and not used in the production of GCL for this project. The following tests shall be performed on each sample:
- Fluid Loss (ASTM D5891) - Swell Index (ASTM D5890)
2.3.1.2 All test results shall be reported and submitted to the Engineer for review and approval. Any sample not conforming to the specified criteria is cause for the material to be rejected. Additional samples will be taken from the same production run to determine the limit of the defective run.
2.19 02236-5 394.107.001 SECTION 02236
GEOSYNTHETIC CLAY LINING MATERIAL (GCL)
2.3.2 Finished Product:
2.3.2.1 Each roll shall be weighed upon production. The roll weight, length, width and lot number shall be recorded on the label attached to the roll.
2.3.2.2 The following tests shall be performed at the minimum frequency shown with the results reported to the Engineer for approval:
- Bentonite Content (ASTM D5993) (the mass per unit area at a 0% moisture content) - every 40,000 square feet - Grab Strength (ASTM D6768) - every 200,000 square feet - Peel Strength (ASTM D6496) - every 40,000 square feet - Permeability - verified by weekly Index Flux Test (ASTM D5887) - in addition, submit last 20 weekly values prior to production of this material for review by the Engineer - Hydrated Internal Shear Strength (ASTM D5321 and D6243) - verify using Peel Strength as an indicator of internal shear strength - in addition, submit last 20 weeks of summary results for review by the Engineer
2.3.2.3 At a maximum of every 750,000 square feet of material produced, a triaxial permeability test shall be performed using the falling head method with a 4 inch flexible wall permeameter (ASTM D5084). The material shall be fully hydrated prior to permeation and permeated at 80 psi confining pressure, 77 psi head pressure, and 75 psi tail pressure.
2.3.2.4 If any test results on the finished product do not fall within the acceptable criteria, additional samples shall be cut and tested from the two adjacent rolls before and after the defective roll. If both rolls are found to be acceptable, the defective roll will be scrapped. If either one of the adjacent rolls fail the quality control testing, additional samples will be taken to isolate the sub-standard region of the production run, and the defective rolls will be scrapped.
2.3.3 All required quality control documentation of the specific GCL lots dedicated for this project will be certified and signed by the Quality Control Manager at the manufacturing plant. This information will be submitted to the Engineer for approval at no additional expense to the Owner. This documentation will include results from the quality control testing of the raw bentonite and the finished GCL product as outlined in this Section.
2.19 02236-6 394.107.001 SECTION 02236
GEOSYNTHETIC CLAY LINING MATERIAL (GCL)
2.4 ADDITIONAL TESTING AND SAMPLING REQUIREMENTS:
2.4.1 At a maximum of every 100,000 square feet of material delivered to the site, one triaxial permeability test shall be performed using the falling head method with a 4-inch flexible wall permeameter (ASTM D5084). The material shall be fully hydrated prior to permeation and permeated under a minimum confining stress of 80 psi, 77 psi head pressure and 75 psi tail pressure. Samples shall be 3 feet long by the roll width and shall not be taken from any portion of a roll which has been subjected to excess pressure or stretching. The Engineer shall mark the machine direction on the samples with an arrow. The Contractor shall take measures to seal the end of the GCL after sampling to minimize the loss of bentonite from the roll. The Engineer may approve taking this test at the manufacturing facility.
2.4.2 For each lot number of GCL material that arrives at the site, a sample shall be taken by the Contractor and provided to the Owner for archiving. This sample shall be 3.0 long by the width of the roll.
2.4.3 Conformance samples may be taken at manufacturing facility with Engineer’s approval. If the Contractor elects to take conformance samples at the manufacturer’s facility rather than on-site in the presence of the Engineer, the Contractor shall provide chain of custody forms from the sampling location to the independent laboratory to the site. All conformance test results shall be submitted a minimum of seven days prior to installation. No materials shall be installed until acceptable test results are approved by the Engineer.
PART 3 - EXECUTION
3.1 GCL INSTALLATION:
3.1.1 Subgrade Preparation:
3.1.1.1 Installation of the GCL shall not begin until a proper subbase has been prepared and accepted by the Engineer and the Installer has certified, in writing, that the final soil surface on which the GCLs are to be installed are acceptable.
3.1.1.2 The exposed subgrade material shall be free from loose earth, fully exposed rocks larger than 1/2 inches, rubble and other foreign matter. The surface upon which the GCL is to be placed shall be maintained in a firm, clean, dry and smooth condition during GCL installation.
3.1.2 GCL Deployment:
2.19 02236-7 394.107.001 SECTION 02236
GEOSYNTHETIC CLAY LINING MATERIAL (GCL)
3.1.2.1 The GCL will be installed with the nonwoven geotextile side up.
3.1.2.2 Placement of the GCL panel will be according to the Contract Drawings. The Contractor shall submit to the Engineer for approval the location and position plan of each panel. Placement will follow all instructions on the wrapping containing the GCL materials which describe the proper methods of unrolling panels. The field panel installation schedule is left to the preference of the Contractor, but the method chosen must minimize erosion of the underlying soil liner and the potential for wind damage.
3.1.2.3 The method of placement must ensure that:
- No equipment used will damage the GCL by handling, trafficking, or other means. Equipment, including ATVs, will not be allowed to travel directly on the material during the installation of overlying soils or geosynthetic layers unless otherwise determined by the Engineer.
- No personnel working on the GCL will smoke, wear damaging shoes, or engage in other activities which could damage the GCL.
- The prepared surface underlying the GCL must not be allowed to deteriorate after acceptance and must remain acceptable up to the time of GCL placement and until completion of the project.
- Any damage to the GCL panels or portions of the panels as a result of placement must be replaced or repaired by the Contractor (at the direction of the Engineer) at no additional cost to the Owner.
- At no time shall the GCL panels be dragged over the surface, except for slight shifting necessary for the adjustment of the overlap, or allowed to roll down any slope.
- The GCL will be placed over the prepared surface in such a manner as to assure minimum handling. The panels shall be placed in such a manner as to allow a six (6) inch overlap, as described in Paragraph 3.1.3, on longitudinal seam and twenty-four (24) inches on horizontal seams. The cover material shall be placed over the GCL during the same day as the placement of the GCL. Only those GCL panels which can be anchored and covered that same day shall be unpackaged and placed in position.
- The GCL shall not be installed in standing water or during rain. The GCL must be dry when installed and must be dry when covered. Any GCL panel that becomes wet and/or hydrated as determined by the Engineer shall be removed and replaced at the
2.19 02236-8 394.107.001 SECTION 02236
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Contractors expense. The damaged panel shall not be reused for this project and shall be removed from the site.
- Installation will be restricted to days when wind conditions at the site are below those limited by the manufacturer’s specification. During the days when the wind conditions are below the manufacturers specification, the Contractor will be responsible for providing (at their own expense) adequate temporary loading and/or anchoring (e.g., sand bags, tires), not likely to damage the GCL, to prevent uplift by wind as determined by the Engineer.
- The GCL shall be installed in a relaxed condition and shall be free of tension or stress upon completion of the installation. Stretching of the GCL to fit will not be allowed. The GCL shall be straightened to smooth out creases of irregularities in the runs.
- The Engineer will assign an "identification number" to each GCL panel placed. This number will be consistent with the number used by the Installer. The number system used will be simple, logical and identify the relative location in the field.
3.1.2.4 The Contractor will be liable for all damages to the materials incurred prior to and during transportation to the site.
3.1.2.5 Handling, storage and care of the GCL rolls prior to and following installation at the site, is the responsibility of the Contractor. The Contractor will be liable for all damages to the materials incurred prior to final acceptance of the lining system by the Owner.
3.1.2.6 The Contractor shall perform field needle detection for all GCL panels placed on the job site. Any detected needles shall be removed. Each roll shall also be visually inspected for sheet defects prior to primary geomembrane placement.
3.1.3 Seaming:
3.1.3.1 Once the first run has been laid, adjoining runs shall be laid with a six (6) inch minimum overlap on the longitudinal seams and twenty-four (24) inch on end seams.
3.1.3.2 Six inch overlap marks shall be marked longitudinally on the GCL by the Manufacturer to assist in obtaining the proper overlap. All dirt, gravel of other debris shall be removed from the overlap area.
3.1.3.3 All seam overlaps shall be placed such that the direction of flow is from the top sheet to the bottom sheet to form a shingle effect.
2.19 02236-9 394.107.001 SECTION 02236
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3.1.3.4 All seams shall be bentonite-enhanced using a continuous bead of granular sodium bentonite along the defined edge of the underlying panel and the 6-inch line unless otherwise approved by the Engineer. A similar bead shall be applied to the 24-inch end seams. The bentonite shall be applied at a minimum application rate of one quarter pound per lineal foot.
3.1.4 GCL Repair:
3.1.4.1 Irregular shapes, cuts, or tears in installed bentonite liner shall be covered with sufficient additional liner to provide a twelve inch overlap on all adjoining liner. Dry bentonite or bentonite mastic shall be applied around the damaged area prior to placement of the patch.
3.1.5 GCL Cover Material:
3.1.5.1 The GCL will be covered with a 60 mil textured HDPE geomembrane (see Section 02596). A temporary slip sheet will be used to minimize friction during textured geomembrane placement and to allow the textured geomembrane to be more easily moved into its final position. To prevent premature hydration, only the amount of GCL that can be inspected, repaired and covered in the same day shall be installed.
3.1.5.2 Once the GCL is covered by a geomembrane, it will be the Contractors responsibility to ensure that no water can travel underneath the geomembrane and prematurely hydrate any GCL panels. Should a GCL panel(s) become wet or hydrated as determined by the Engineer, the Contractor, at their own expense, shall remove the geomembrane, remove the damaged GCL panel(s), replace the damaged GCL panel(s), and cover the replaced GCL panel(s). The damaged panel(s) shall not be reused for this project and shall be removed from the site.
3.1.5.3 Any leading edge of panels of GCL left unprotected must be covered with a heavy, waterproofing tarp which is adequately secured and protected with sand bags or other ballast.
3.1.5.4 Deployment equipment used to install cover shall not operate directly on the GCL.
3.2 POST-CONSTRUCTION:
3.3 WARRANTY:
3.3.1 The Contractor shall obtain and submit to the Engineer from the Manufacturer and Installer separate written warranties guaranteeing for a 1-year period from Notice of Substantial Completion that the GCL materials and workmanship specifically provided or performed under this Contract shall be free from defects.
2.19 02236-10 394.107.001 SECTION 02236
GEOSYNTHETIC CLAY LINING MATERIAL (GCL)
PART 4 – MEASUREMENT & PAYMENT
4.1 MEASUREMENT – GEOSYNTHETIC CLAY LINING MATERIAL (GCL):
4.1.1 Measurement for payment for Geosynthetic Clay Lining Material (GCL) shall be based on the number of square feet of material placed as measured to the nearest square foot of area covered by the GCL. Extra material at the seams will not be paid for.
4.2 PAYMENT – GEOSYNTHETIC CLAY LINING MATERIAL (GCL):
4.2.1 For Geosynthetic Clay Lining Material (GCL), not included in other unit or lump sum price items, payment for Geosynthetic Clay Lining Material (GCL) will be made at the applicable price stated in the Bid.
4.2.2 The Owner shall pay for the cost of material delivered and properly stored on-site upon receipt of all submittals and acceptable conformance test results. After installation of the material, the Owner shall retain 10% of the price of the Geosynthetic Clay Lining Material (GCL) until the Contractor provides an acceptable warranty.
END OF SECTION
2.19 02236-11 394.107.001 SECTION 02237
COMPOSITE GEONET
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment to install a factory welded/heat laminated geocomposite consisting of geonet sandwiched between 6 oz/sq. yd nonwoven geotextile (both sides), as shown on the Plans, as specified, and/or directed.
1.1.2 Composite geonet will be used in the secondary leachate collection system as well as the pore water drainage layer.
1.2 SUBMITTALS:
1.2.1 Prior to the installation or delivery of composite geonet, the Contractor shall submit to the Engineer, from the geosynthetic manufacturer, guaranteed properties of the geonet, geotextile, and composite geonet to be used in construction, as outlined in Article 2.2 of this Section. The Contractor shall provide the Engineer, from the manufacturer, a written certification stating that the materials meet or exceed the guaranteed properties submitted.
1.2.2 In addition to submitting guaranteed physical properties, the Contractor shall submit to the Engineer the following documentation:
• A sample of Composite Geonet (6-inch x 6-inch minimum). • Copies of quality control certificates issued by the raw material supplier. • Results of tests conducted to verify the quality of the resin used to manufacture the composite geonet rolls assigned to the project. • Certification that no post consumer reclaimed polymer is added to the resin during manufacturing. Rework material of the same or similar resin type is allowed up to 10%. • Documentation demonstrating the chemical compatibility of the materials with leachate generated from mixed municipal solid waste. Such documentation shall include chemical compatibility testing results. • Manufacturing quality control (QC) certificates for the geotextile material used in composite geonet manufacturing, signed by a responsible party of the manufacturer. QC certificates shall include role numbers and identification and results of QC tests including test methods.
1.2.3 Transmissivity Testing Requirements:
6.19 02237-1 394.107.001 SECTION 02237
COMPOSITE GEONET
1.2.3.1 One performance transmissivity test result shall be submitted to the Engineer by the Contractor demonstrating that the composite geonet intended for use in liner construction meets the required transmissivity for the following conditions:
• Test Method: ASTM D4716 • Boundary Conditions: - Steel Plate - Site Specific Structural Fill - Composite Geonet - 60 mil textured HDPE Geomembrane - Steel Plate
• Normal Load: 20,000 psf • Gradient: 0.10 • Seat Time: 100 hrs
The required performance transmissivity for this project is 1.0 x 10-4 m2/sec. The composite geonet shall be tested in the direction as to be installed in the field.
1.2.3.2 Index transmissivity testing shall be performed on the same material tested for performance transmissivity in accordance with ASTM D4716. The test conditions shall include testing the composite geonet between two steel plates at the normal load and gradient above. The seat time shall be 15 minutes. A minimum of three complete index transmissivity test results shall be submitted to the Engineer by the Contractor.
1.2.4 Prior to delivery, the Contractor shall submit a construction drawing(s) illustrating the following aspects of the composite geonet installation:
- panel or sheet layout - location and orientation of field seams or overlap splices - any variances from the Contract Drawings - any required details
1.2.4.1 The layout must be reviewed and approved by the Engineer prior to installation. All plans and details will be dimensional and of adequate scale to be used during construction.
1.2.5 Pre-Qualification: The Contractor shall submit the following information to the Engineer, for approval of the installer.
1.2.5.1 Copy of installer's letter of approval or license by the manufacturer and/or fabricator.
6.19 02237-2 394.107.001 SECTION 02237
COMPOSITE GEONET
1.2.5.2 Corporate background and information.
1.2.5.3 Description of installation capabilities, including:
a. information on equipment and personnel; b. average daily production anticipated; and c. quality control procedures.
1.2.5.4 Resume of the field engineer or installation supervisor to be assigned to this project, including dates and duration of employment.
1.2.6 Prior to delivery, the Contractor shall submit a sample of the warranty to be provided as described in paragraph 3.3.1.
1.3 DELIVERY:
1.3.1 All composite geonet will be inspected on delivery, and materials that do not comply with the Specification will be rejected. The Contractor shall furnish all labor required to handle the composite geonet during inspection and shall remove the rejected material from the site of the work.
1.4 CONFORMANCE TESTING:
1.4.1 Within one week of delivery and at the Engineer’s direction, the Contractor shall provide the necessary labor, tools and equipment to obtain samples from the rolled composite geonet material, and send these samples to an independent quality assurance laboratory for testing at the Contractor’s expense. As a minimum, the following tests will be performed on all composite geonets:
HDPE Geonet Core: - carbon black content - ASTM D4218 - density - ASTM D1505 - thickness - ASTM D5199
Composite Geonet: - ply adhesion (both top and bottom interfaces) - ASTM D7005 - index transmissivity - ASTM D4716 - interface friction testing according to Section 02599
6.19 02237-3 394.107.001 SECTION 02237
COMPOSITE GEONET
1.4.2 Samples will be taken by cutting along the width and 5 feet from the end of a rolled or folded geosynthetic material. The sampling frequency for the composite geonet will be one sample per every 100,000 square feet of respective material delivered.
1.4.3 For each lot number of composite geonet that arrives at the site, a sample shall be taken by the Contractor and provided to the Owner for archiving. This sample shall be 3 feet by the width of the roll of composite geonet.
1.4.4 The Engineer may approve conformance sampling at the manufacturing facility. Conformance test results shall be submitted a minimum of seven days prior to installation. No materials shall be installed prior to the receipt of acceptable test results.
PART 2 - PRODUCTS
2.1 MATERIALS:
2.1.1 Composite Geonet:
2.1.1.1 The composite geonet to be utilized in the landfill construction shall consist of a profiled mesh made by extruding a minimum of two sets of high density polyethylene strands together to form a bi-planar or tri-planar drainage net, sandwiched between and factory welded/heat-laminated to 6 oz./sq. yd. non-woven geotextile fabric layers (both sides). The resultant structure shall provide a high flow along the plane of the net. Composite geonet shall be produced and/or distributed by GSE Lining Technology, Tenax Corporation, SKAPS, or approved equal.
2.1.1.2 The composite geonet shall be protected from mud, dirt, dust, tearing, puncture, or any other damaging condition during shipment and storage. The composite geonet shall be capable of withstanding direct outdoor exposure for at least one year.
2.1.1.3 The composite geonet must be capable of retaining its structure during handling, placement, and long-term loading. Foamed HDPE products shall not be accepted.
2.1.1.4 The composite geonet shall be delivered on-site in bound rolls tagged with the following information:
- manufacturer's name - product identification - lot number - roll number and dimensions 6.19 02237-4 394.107.001 SECTION 02237
COMPOSITE GEONET
2.2 MINIMUM SPECIFIED VALUES:
2.2.1 Geonet Core Typical Specifications:
2.2.1.1 The table below lists the typical specification values for HDPE high compression load geonet. Final approval of geonet properties shall be made by the Engineer based upon Contractor's submittals.
TABLE 2A TYPICAL DRAINAGE NET CORE PROPERTIES
PROPERTY TEST METHOD VALUE UNITS
Thickness ASTM D5199 250 (min.) mil
Tensile Strength (MD / CD) ASTM D5036/7179 50 / 25 (min.) lb/in
Density ASTM D1505 0.940 (min.) g/cm3
Melt Flow Index ASTM D1238 1.1 (max.) g/10 min
Carbon Black Content ASTM D4218 2 (min.) %
MD = Machine Direction CD = Cross Direction
6.19 02237-5 394.107.001 SECTION 02237
COMPOSITE GEONET
2.2.2 Geotextile Typical Specifications:
TABLE 2B TYPICAL GEOTEXTILE PROPERTIES
PROPERTY TEST METHOD VALUE UNITS
Mass Per Unit Area ASTM D5261 6 (MARV) oz/sy
AOS ASTM D4751 70 (MARV) US Sieve
Permitivity ASTM D4491 1.3 (MARV) sec-1
Permeability ASTM D4491 0.2 (MARV) cm/sec
Grab Tensile Strength ASTM D4632 160 (MARV) lbs
Grab Elongation ASTM D4632 50 (MARV) %
Trapezoid Tear ASTM D4533 65 (MARV) lbs
CBR Puncture Strength ASTM D6241 475 (min.) lbs
UV Resistance @ 500 hrs ASTM D4355 70 (min) %
MARV = Minimum Average Roll Value
2.2.3 Composite Geonet Typical Specifications:
PROPERTY TEST METHOD VALUE UNITS
Ply Adhesion ASTM D7005 1.0 (min.) lb/in
Performance Transmissivity ASTM D4716 See Article m2/sec 1.2.3.1
6.19 02237-6 394.107.001 SECTION 02237
COMPOSITE GEONET
PART 3 - EXECUTION
3.1 COMPOSITE GEONET INSTALLATION:
3.1.1 The following procedures and requirements will be followed during the installation of composite geonets.
3.1.2 Placement:
3.1.2.1 The placement of composite geonets shall not be conducted during adverse weather conditions. All composite geonets will be secured with sandbags or an equivalent approved anchoring system. Removal of the sandbags or equal will only occur upon placement of an overlying soil layer or geosynthetic.
3.1.2.2 Proper cutting tools shall be used to cut and size the composite geonet material. Extreme care will be taken while cutting in-place geosynthetics, to obviate concerns of damaging underlying geomembrane liners or geosynthetic materials.
3.1.2.3 During the placement of composite geonets, all dirt, dust, sand or mud shall be kept off to prevent clogging. If contaminant materials are present on the composite geonet, then the net shall be hosed down with water until the contaminants are flushed free. Prior to placement of an overlying geosynthetic, the Engineer will verify that the geonet is free of potential clogging materials. If excessive contaminant materials are present on the geonet, it shall be cleaned or replaced as directed by the Engineer.
3.1.2.4 No equipment used will damage the composite geonet by handling, trafficking, or other means. Low ground pressure rubber tire equipment (less than 5 psi), including ATVs, will not be allowed to travel directly on the material during the installation of overlying soils or geosynthetic layers, without prior approval by the Engineer. Sudden acceleration, deceleration or turning of the equipment on the composite geonet is prohibited. Any damage to the material from the equipment shall be repaired by the Contractor at no additional cost to the Owner.
3.1.2.5 Generally, all panels/rolls shall be orientated parallel to the line of slope, not across slope. This applies to all slopes in excess of 10 percent grade.
3.1.3 Seaming or Joining:
3.1.3.1 Composite Geonets:
6.19 02237-7 394.107.001 SECTION 02237
COMPOSITE GEONET
3.1.3.1.1 Composite geonets will be joined using the following procedures:
a. Adjacent rolls will be placed such that the geotextile is overlapped by at least 3 inches and the geonet overlapped by at least 4 inches.
b. The top geotextile overlap will be continuously sewn and the bottom geotextiles will be overlapped. Geonet overlaps will be secured by tying.
c. Tying can be achieved by plastic fasteners, or polymer braid. All ties will be white or yellow for easy observation.
d. Tying will be every 5 feet along the slope, every 2 feet across the slope and every 6 inches in the anchor trench. Tying will be every 10 feet on slopes less than 10%.
e. In the corners of the side slopes, where overlaps between perpendicular geonet strips are required, an extra layer of geonet will be unrolled along the slope, on top of the previously installed geonets, from top to bottom of the slope.
f. All free ends of composite geonet to be covered with fine grain soil shall be wrapped with geotextile to prevent fines from clogging the geonet core, as directed by the Engineer.
g. At butt seams, the geonet shall be overlapped a minimum of 2-feet and tying will be every 2-feet. An additional geotextile shall be installed over the butt seam and heat laminated in place.
3.1.3.1.2 All damage to geonet will be repaired by placing geonet material over the damaged area with an overlap of 2 feet and then tying the patch every 6 inches using an approved tying method. Where damage to a geonet is greater than 50 percent of the roll width, the damaged portion will be removed and a new length of geonet spliced into the open area using the tying procedures above.
3.2 POST-CONSTRUCTION
3.2.1 Upon completion of the installation, the Contractor shall submit to the Engineer:
a. All quality control documentation to the Engineer.
b. The warranty obtained from the manufacturer/fabricator.
6.19 02237-8 394.107.001 SECTION 02237
COMPOSITE GEONET
3.3 WARRANTY:
3.3.1 The Contractor shall obtain and submit to the Engineer from the manufacturer a standard warranty provided for the composite geonet. The warranty shall guarantee that the composite geonet shall remain free from defects for a minimum of one (1) year from the date of substantial completion of the project. The Engineer will review the warranty for completeness prior to the Owner accepting its provisions.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - COMPOSITE GEONET:
4.1.1 Measurement for payment for Composite Geonet shall be based on the number of square feet placed in plan view as measured to the nearest foot excluding any overlaps, waste, and material in the anchor trench.
4.2 PAYMENT - COMPOSITE GEONET:
4.2.1 For Composite Geonet, not included in other unit or lump sum price items, payment for Composite Geonet will be made at the applicable price stated in the Bid.
4.2.2 The Owner shall pay for the cost of material delivered and properly stored on site upon receipt of all submittals and acceptable conformance test results. After installation of the material, the Owner shall retain 10 percent of the price of Composite Geonet until the Contractor provides the quality control documentation and the acceptable warranty.
END OF SECTION
6.19 02237-9 394.107.001 SECTION 02255
COMMON FILL MATERIAL
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Common Fill Material, as shown on the Plans, as specified, and/or directed.
1.1.2 Work under this Section shall include, but not necessarily be limited to excavating, transporting, dumping, spreading, compacting, and testing common fill material in the locations and to the depths and grades shown on the Contract Drawings, or as directed by the Engineer.
1.1.3 Common Fill will be used to construct the landfill subgrade and groundwater diversion berm, or as directed by the Engineer.
PART 2 - PRODUCTS
2.1 MATERIALS:
2.1.1 Common Fill Material shall be natural soil, free from excessive moisture, frost, stumps, trees, roots, sod, muck, marl, vegetable matter or other unsuitable materials.
2.1.2 Common Fill Material used shall be on-site till mined from Borrow area No. 3, as shown on the Contract Drawings. Acceptable on-site borrow shall be well graded from fine to coarse. Stones, if any, shall not exceed six (6) inches in greatest dimension. All materials shall be suitable for compaction in layers not exceeding twelve (12) inches in loose thickness and shall remain stable when wet.
PART 3 - EXECUTION
3.1 PLACEMENT:
3.1.1 The entire surface to be covered with common fill shall be stripped of all grass, vegetation, top soil, rubbish, roots, organic materials or other unsuitable deleterious materials before backfilling.
6.19 02255-1 394.107.001 SECTION 02255
COMMON FILL MATERIAL
3.1.2 In general, common fill shall be placed in horizontal layers not exceeding twelve (12) inches in loose thickness and shall be compacted according to the criteria and tolerances of Paragraph 3.3. Stones, if any, shall not exceed six (6) inches in greatest dimension and shall be well distributed throughout the mass. Subgrade for common fill shall be approved by the Engineer. Where common fill is to be constructed across ground which will not support the weight of the construction equipment, the soft soils shall be excavated and replaced with suitable backfill as approved by the Engineer, at no additional cost to the Owner.
3.1.3 Each layer of common fill material shall be thoroughly tamped or rolled to the required degree of compaction by sheepsfoot, mechanical tampers, or vibrators. Successive layers shall not be placed until the layer under construction has been thoroughly compacted.
3.1.4 Padfoot rollers shall be used wherever possible to compact common fill soil and shall have a weight on each row of feet of not less than two hundred (200) nor more than five hundred (500) pounds per square inch of foot surface.
3.1.5 Trucks or other heavy equipment shall not be operated over pipelines until a minimum of twenty-four (24) inches of backfill above the crown of the trenched pipe has been placed and properly compacted by tampers or other approved method.
3.1.6 Where required, the Contractor shall, at his own expense, moisture condition the fill to meet the compaction requirements of the specification. If, due to rain or other causes, the material is too wet for satisfactory compaction, it shall be allowed to dry or be removed as required, before compaction, at no additional cost to the Owner.
3.2 FIELD TESTING AND QUALITY CONTROL:
3.2.1 Common fill shall be compacted to a minimum dry density of ninety (90) percent of the maximum dry weight density in pounds per cubic foot as determined by the Modified Proctor Compaction Test, ASTM D1557 unless otherwise noted on the Contract Drawings or Specifications. Modified Proctor, Grain Size Analyses (ASTM D422 and 2217) and Atterberg Limits (ASTM D4318) shall be performed for each 5,000 cubic yard of fill placed by an independent testing laboratory at the Contractor's expense.
3.2.2 Compaction curves shall be developed for use of the common fill material. The development of the curves from the Modified Proctor Compaction Test shall be done by an approved testing laboratory at the Contractor's expense.
6.19 02255-2 394.107.001 SECTION 02255
COMMON FILL MATERIAL
3.2.3 Field control samples shall be taken as directed by the Engineer during the construction to verify that the Proctor density limits and grain size distribution are consistent and that the common fill is uniform. Such samples shall be taken and tested by the soils quality assurance laboratory at the Contractor's expense. In-place density testing according to ASTM D6938, D2922, D2167 or D1556 procedures will be conducted at the frequencies given below:
- in-place testing will be performed at a frequency of one per 5,000 square feet per lift of common fill and at final subgrade elevation.
3.2.4 All in-place density tests will be located according to an approved testing grid system. Elevations will be established from known existing benchmarks by Contractor. Contractor shall establish the grid system in the field such that work areas can be easily located by the Engineer.
3.2.5 Common fill shall be constructed to such heights as to make allowance for after- construction settlement and any settlements which occur before final acceptance of the Contract shall be corrected to make the backfill conform with the established lines and grades.
3.2.6 The subgrade will be proof-rolled upon completion to the satisfaction of the Engineer and tested for density and moisture content at a minimum frequency of nine (9) tests per acre. Prior to proof rolling the subgrade, a description of the equipment that shall be used for the operations shall be submitted to the Engineer for approval.
3.3 CRITERIA AND TOLERANCES:
3.3.1 Criteria and tolerances of common fill are as follows:
- Compaction - a minimum of 90 percent of the maximum dry density as determined by the Modified Proctor Method unless otherwise specified or directed.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - COMMON FILL MATERIAL:
4.1.1 Measurement of the quantity of Common Fill Material, allowed for payment, shall be computed, after compaction, by using the product of the length, depth as directed, and the actual width, but not to exceed the established lines as shown on the drawings or as directed by the Engineer, less the volume occupied by any pipe or structures, if any.
6.19 02255-3 394.107.001 SECTION 02255
COMMON FILL MATERIAL
4.2 PAYMENT - COMMON FILL MATERIAL:
4.2.1 For Common Fill Material, not included in other unit or lump sum price items, payment for Common Fill Material will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 02255-4 394.107.001 SECTION 02258
STRUCTURAL FILL MATERIAL
PART 1 – GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Structural Fill Material, as shown on the Plans, as specified, and/or directed.
1.1.2 Work under this Section shall include, but not necessarily be limited to excavating, processing, transporting, dumping, spreading, compacting, and testing structural fill material in the locations and to the depths and grades shown on the Contract Drawings or as directed by the Engineer.
1.1.3 Structural Fill will be used in the primary composite liner system directly above the secondary leachate collection layer and below the geosynthetic clay liner (GCL).
PART 2 - PRODUCTS
2.1 MATERIALS:
2.1.1 Structural Fill Material shall be natural soil, free from excessive moisture, frost, stumps, trees, roots, sod, muck, marl, vegetative matter or other unsuitable materials.
2.1.2 Structural Fill Material shall consist of clean, sound, medium to coarse sand or round stone, less than 1-inch in the maximum dimension and free from organic material and coatings. In addition, the material shall possess a minimum permeability of 1.0 x 10-1 cm/sec at a relative density of 90 percent and shall have no more than three percent passing the No. 200 sieve.
2.1.3 Material to be used for Structural Fill shall have a calcium carbonate content of less than 15% as determined by the methodology outlined in ASTM D3042. The test shall be run using distilled vinegar in place of hydrochloric acid as specified in ASTM D3042.
2.2 SUBMITTALS:
2.2.1 The Contractor shall submit to the Engineer for approval a certified sieve analysis, minimum permeability, calcium carbonate content, and the minimum and maximum relative densities as determined by an independent testing laboratory, at no additional cost to the Owner. All tests will be performed in accordance with the methods outlined in this Section.
6.19 02258-1 394.107.001 SECTION 02258
STRUCTURAL FILL MATERIAL
PART 3 – EXECUTION
3.1 PLACEMENT:
3.1.1 The structural fill material shall be placed directly over the composite geonet of the secondary leachate collection layer in one 12-inch lift. Placement shall be by low ground pressure tracked equipment with ground pressures not exceeding 5 pounds per square inch. All rubber tired vehicles will access construction above geosynthetics from temporary access roads built a minimum three feet above the geosynthetics. Extra geotextiles or geomembrane layers shall be placed on or beneath all access roads or in high traffic areas. Any placement technique which results in damage of the underlying geosynthetic, or in the opinion of the Engineer, has the potential of damaging the underlying geosynthetics, shall be immediately cease and be modified to prevent such damage.
3.1.2 Placement shall be in a systematic manner without damage to the underlying geosynthetic materials. Structural fill must be placed using vertical placement techniques. No horizontal pushing of the structural fill will be allowed.
3.1.3 The final surface of the structural fill material shall be fined graded to the minimum depth shown on the Contract Drawings. Compaction of the structural fill shall be by the weight of the bulldozer and/or a smooth drum roller. The final surface shall be firm, clean, dry and in a smooth condition for installation of the GCL.
3.2 FIELD TESTING AND QUALITY CONTROL:
3.2.1 In-place density will be visually approved by the Engineer for the Structural Fill material with field density tests performed as requested by the Engineer at the Contractor’s expense.
3.2.2 The Contractor shall perform one grain size analysis (ASTM C316/ASTM C117) and one laboratory permeability test (ASTM D2434) for every 2,500 cubic yards of stockpiled material as it is delivered to the site.
3.2.3 In addition to field density testing, the following laboratory testing will be performed at the Contractor’s expense by an independent testing laboratory on samples of structural fill. All samples of materials will be taken from in-place material in the Engineer’s presence.
a. One grain size analysis (ASTM C136 & C117) every 1,000 cubic yards of in-place material, or as directed by the Engineer.
6.19 02258-2 394.107.001 SECTION 02258
STRUCTURAL FILL MATERIAL
b. One laboratory permeability test in accordance with ASTM D2434 per every 2,500 cubic yards of in-place material, or as directed by the Engineer.
3.3 CRITERIA AND TOLERANCES:
3.3.1 Criteria and tolerances of the select fill material are as listed in Article 2.1.
PART 4 – MEASUREMENT & PAYMENT
4.1 MEASUREMENT – STRUCTURAL FILL MATERIAL
4.1.1 Measurement of the quantity of Structural Fill Material, allowed for payment, shall be computed, after compaction, using the product length, depth as directed, and the actual width, but not to exceed the established lines shown on the drawings or as directed by the Engineer, less the volume occupied by any pipe or structures, if any.
4.2 PAYMENT – STRUCTURAL FILL MATERIAL
4.2.1 For Structural Fill Material, not included in other unit or lump sum price items, payment for Structural Fill Material will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 02258-3 394.107.001 SECTION 02271
RIPRAP
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Riprap, as shown on the Plans, as specified, and/or directed.
1.1.2 The Contractor shall furnish all plant, labor, equipment and materials and perform all work necessary to place a protective covering of erosion-resistant Riprap at locations shown on the Plans and as directed by the Engineer. The work shall be done in accordance with these specifications and in conformity with the lines and grades shown on the Plans or established by the Engineer. The type of Riprap to be used shall be as indicated on the Contract Drawings.
PART 2 - PRODUCTS
2.1 RIPRAP:
2.1.1 Stone used for Riprap shall be hard, durable, angular in shape, resistant to weathering and to water action, free from overburden, spoil, shale and organic material, and shall meet the gradation requirements for the type specified. Neither breadth nor thickness of a single stone should be less than one-third its length. Rounded stone or boulders will not be accepted unless authorized by the Engineer. Broken concrete may be substituted for stone when authorized by the Engineer. Shale and stone with shale seams are not acceptable. The minimum unit weight of the stone shall be 155 pounds per cubic foot as computed by multiplying the specific gravity (bulk-saturated-surface-dry basis, AASHTO Test T85) times 62.4 pounds per cubic foot.
2.1.2 The sources from which the stone will be obtained shall be selected for approval by the Engineer well in advance of the time when the stone will be required in the work. The acceptability of the stone will be determined by service records and/or by suitable tests, as required by the Engineer. If testing is required, suitable samples of stone shall be taken in the presence of the Engineer at least 25 days in advance of the time when the placing of Riprap is expected to begin. The approval of some rock fragments from a particular quarry site shall not be construed as constituting the approval of all rock fragments taken from that quarry.
2.1.3 The quality of all material used for Riprap shall be determined by the Magnesium Sulfate Soundness Test, if so elected by the Engineer. A maximum 10 percent loss at ten (10) cycles, by weight, shall be acceptable.
6.19 02271-1 394.107.001 SECTION 02271
RIPRAP
2.1.4 The types of Riprap to be provided shall conform to the following gradation requirements:
Type % Passing Stone Size
I 90-100 Smaller than 8 inches 50-100 Larger than 3 inches 0-10 No. 10
II 90-100 Lighter than 100 lbs. 50-100 Larger than 6 inches 0-10 Smaller than 1/2 inch
III 50-100 Heavier than 100 lbs. 0-10 Smaller than 4 inches
IV 50-100 Heavier than 600 lbs. 0-10 Smaller than 6 inches
2.1.5 Each load of Riprap shall be reasonably well graded from the smallest to the maximum size specified. Stones smaller than the specified 10 percent size and spalls will not be permitted in an amount exceeding 10 percent by weight of each load.
2.1.6 Control of gradation will be by visual inspection. If requested by the Engineer, the Contractor shall provide two samples of rock of at least 5 tons each, meeting the gradation for the type specified. The sample at the construction site may be a part of the finished Riprap covering. The other sample shall be provided at the quarry. These samples shall be used as a frequent reference for judging the gradation of the Riprap supplied. Any difference of opinion between the Engineer and the Contractor shall be resolved by dumping and checking the gradation of two random truck loads of stone. Mechanical equipment, a sorting site, and labor needed to assist in checking gradation shall be provided by the Contractor at no additional cost to the Owner.
2.1.7 In addition to meeting the gradation requirements set forth in this section for the type of Riprap indicated, Riprap shall consist of stones shaped as nearly as practicable in the form of right rectangular prisms. One dimension of the majority of the stones furnished shall be at least equal to the thickness as shown on the Plans.
6.19 02271-2 394.107.001 SECTION 02271
RIPRAP
2.2 BEDDING:
2.2.1 Bedding material shall be provided below the Riprap if indicated on the Plans or directed by the Engineer. Bedding material shall be composed of crushed stone, crushed air cooled blast furnace slag, or gravel, free of soft nondurable particles, organic material, and thin or elongated particles.
2.2.2 Bedding material shall meet the following gradation requirements:
Sieve Designation % Passing
4 inches 100
1 inch 15-60
1/4 inch 0-25
No. 40 0-10
PART 3 - EXECUTION
3.1 PLACEMENT:
3.1.1 Slopes to be protected by Riprap shall be free of brush, topsoil, trees, stumps, and other objectionable material and shall be dressed to a smooth surface. All soft or spongy material shall be removed to the depth shown on the Plans or as directed by the Engineer and replaced with approved material. Filled areas will be compacted as specified. If shown on the Plans, a toe trench shall be dug and maintained until the Riprap is placed.
3.1.2 Protection for structure foundations shall be provided as early as the foundation construction permits. The area to be protected shall be cleaned of waste materials and the surfaces to be protected prepared as shown on the Plans. The type of Riprap specified will be placed in accordance with these Specifications.
3.1.3 When shown on the Plans, a bedding material blanket shall be placed on the prepared slope or area to be provided with Riprap as specified in Paragraph 3.2.1 before the stone is placed.
6.19 02271-3 394.107.001 SECTION 02271
RIPRAP
3.1.4 Stone for Riprap shall be placed on the prepared slope or area in a manner which will produce a reasonably well-graded mass of stone with the minimum practicable percentage of voids. The entire mass of stone shall be placed so as to be in conformance with the lines, grades, and thicknesses shown on the Plans. Riprap shall be placed to its full course thickness in one operation and in such a manner as to avoid displacing the underlying material. Placing of Riprap in layers, or by dumping into chutes, or by similar methods likely to cause segregation will not be permitted.
3.1.5 The larger stones shall be well distributed, and the entire mass of stone shall conform to the gradation specified in Paragraph 2.1.4. All material going into Riprap protection shall be so placed and distributed that there will be no large accumulations of either the larger or smaller sizes of stone.
3.1.6 It is the intent of these Specifications to produce a fairly compact Riprap protection in which all sizes of material are placed in their proper proportions. Hand placing or rearranging of individual stones by mechanical equipment may be required to the extent necessary to secure the results specified.
3.1.7 Unless otherwise authorized by the Engineer, the Riprap protection shall be placed in continuous progression with the construction of the embankment. The Contractor shall maintain the Riprap protection until accepted, and any material displaced by any cause shall be replaced to the lines and grades shown on the Plans at no additional cost to the Owner.
3.1.8 When Riprap and bedding material are placed under water, thickness of the layers shall be increased as shown on the Plans; and methods shall be used that will minimize segregation.
3.1.9 Riprap shall be placed so that the dimension approximately equal to the layer thickness is perpendicular to the slope surface and that the weight of the stone is carried by the underlying material and not by the adjacent stones. On slopes, the largest stones shall be placed at the bottom of the slope. The Riprap shall be properly aligned and placed so as to minimize void spaces between adjacent stones. The spaces between the stones shall be filled with spalls of suitable size.
3.2 BEDDING MATERIAL:
3.2.1 Bedding material shall be placed where shown on the Plans or as directed by the Engineer. The bedding material shall be placed on the prepared area to the full specified thickness of each layer in one operation, using methods which will not cause segregation of
6.19 02271-4 394.107.001 SECTION 02271
RIPRAP
particle sizes. Contamination of bedding material by natural soils or other materials shall be prevented at all times. Bedding material that becomes contaminated shall be removed and replaced with uncontaminated bedding material at the Contractor's own expense. Filter fabric shall be placed below the bedding material, if shown on the Plans.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT – RIPRAP:
4.1.1 Measurement for Riprap shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT – RIPRAP:
4.2.1 For Riprap, not included in other unit or lump sum price items, payment for Riprap will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 02271-5 394.107.001 SECTION 02292
SOIL LINER MATERIAL
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Soil Liner Material, as shown on the Plans, as specified, and/or directed.
1.1.2 Work under this Section shall include, but not necessarily be limited to, excavation, transporting, stockpiling, moisture conditioning, screening, dumping, spreading, disk harrowing, compacting, and testing soil liner material in the locations, and to the depths and grades shown on the Contract Drawings or as directed by the Engineer. The soil liner shall be used for secondary soil liner construction or as otherwise shown on the Contract Drawings or as directed by the Engineer.
PART 2 - PRODUCTS
2.1 MATERIALS:
2.1.1 The Contractor may obtain soil liner material from off-site or on-site sources. If on-site material is utilized, the Contractor shall utilize gray glacial till mined from designated areas. Mixing of brown till and gray till is prohibited. Permeability testing of remolded gray glacial till samples have resulted in permeabilities of less than 1x10-7 cm/sec under proper conditions. Use of on-site material for soil liner is at the Contractor’s risk.
2.1.1.1 The Contractor is responsible for performing all stockpile and in-place soil testing (i.e. laboratory, nuclear moisture-density testing, permeability testing, etc.) as outlined herein for all soil liner material.
2.1.2 The soil liner material shall be free from excessive moisture, frost, stumps, tree roots, sod, muck, marl, vegetable matter, refuse or other unsuitable materials. Soil liner material shall be screened to achieve a maximum particle (stone and/or soil clod) size shall be one-inch. Material will be inspected and tested in accordance with Paragraph 3.3. The stockpiled soil liner material shall meet or exceed the criteria given in Paragraph 3.4. Contractor shall use equipment, such as a disk harrow, tiller, water truck, etc., as needed to control the water content within the range necessary to achieve the required permeability. Moisture shall be evenly distributed through the soil layer to be compacted. No dry lift interfaces shall be permitted.
6.19 02292-1 394.107.001 SECTION 02292
SOIL LINER MATERIAL
2.1.3 Moisture-density-permeability relationship will be developed by the Contractor as follows:
1. From proposed material, select five (5) samples that represent an appropriate range of materials. A Modified Proctor test (ASTM D1557), a Moisture Content (ASTM D2216) and an Atterberg Limits test (ASTM D4318) will be performed on each.
2. Perform permeability tests at the following moisture/densities on the high and low proctor.
• Modified Proctor - 95% density at 1% below optimum, 2%, 4% and 6% above optimum; and 90% density at 1% below optimum, 2%, 4% and 6% above optimum.
3. Perform standard and reduced (15 blow) proctor tests on the high-low proctors previously selected. A line of optimums can now be established.
4. From this data, the acceptable permeability envelope can be established and plotted in relation to the line of optimums.
5. The Soils Construction Quality Control Laboratory shall prepare a summary of the moisture-density-permeability relationship which includes a graph showing all proctors, the line of optimums and a plot of all permeability results at the corresponding moisture and density. This report shall be submitted to the Engineer at least 7 days prior to Test Pad construction.
6. The maximum extent of the acceptable permeability shall be established using the line of optimums (left side), zero air voids line (right side), 100% of the high proctor (top) and 90% of an average of the proctor (bottom). The window shall be further revised based on the permeability tests.
PART 3 - EXECUTION
3.1 TEST PAD:
3.1.1 A test pad shall be constructed by the Contractor to verify that the Contractor's intended construction equipment and techniques will achieve the specified results. The test pad shall be constructed outside the limits of the liner extension area in a location designated by the Engineer.
6.19 02292-2 394.107.001 SECTION 02292
SOIL LINER MATERIAL
3.1.2 The test pad will be constructed using the same materials in the same configuration as in the actual groundwater suppression layer and secondary soil liner system. It shall be constructed using the same equipment and methods that will be used to construct the actual components of the liner system mentioned above. Installation shall comply with Section 3.2 and Section 3.3 requirements. The test pad will be a minimum of 60 feet by 50 feet.
3.1.3 Each lift of the secondary soil liner system shall be tested for density and moisture at 100 square foot intervals. All density and moisture test results shall meet the specified requirements for the corresponding layer. Prior to placing the second lift, a portion of the first lift of successfully compacted soil liner material shall be excavated by hand to allow examination of the underlying geosynthetic for damage. Prior to placing the third lift, a portion of the lift below shall be excavated by hand to allow observation of interlift bonding. If necessary, the test pad procedures shall be modified to promote better interlift bonding.
3.1.4 Upon completion of each lift of the secondary soil liner system, one (1) Shelby tube sample shall be extracted at a location determined by the Engineer. Each Shelby tube sample shall be tested for permeability using an approved triaxial permeability test with back pressure (ASTM D5084).
3.1.5 Additional bulk soil samples shall be obtained adjacent to the Shelby tube locations and tested as follows:
- ASTM D422 - Soil Grain Size Analysis
- ASTM D4318 - Liquid and Plastic Limits of Soil
- ASTM D2216 - Moisture Content Determination
- ASTM D1557 - Modified Proctor Density
3.1.6 Upon extraction of a Shelby tube sample, the remaining hole will be properly filled with powdered bentonite.
3.1.7 If the test results for secondary soil liner components of the liner system comply with the specified values for permeability, the Contractor may proceed with construction of the landfill liner system. If the permeability results are unsatisfactory, the Contractor must modify his construction equipment and/or methods and reconstruct the test pad until satisfactory results are achieved. The actual equipment and methods used to construct an acceptable test pad shall be used to construct the entire landfill liner system.
6.19 02292-3 394.107.001 SECTION 02292
SOIL LINER MATERIAL
3.1.8 All test pad results shall be compiled and compared to the moisture-density permeability relationship established prior to test pad construction (Section 2.1.2) to be used as a guide by the Contractor for the installation of soil liner materials. If the Contractor modifies the moisture-density-permeability relationship based on test pad results an additional test pad shall be constructed to verify the installation of the soil liner material.
3.2 INSTALLATION:
3.2.1 Subgrade shall be prepared by excavation or fill as required in order to achieve the subgrade elevations as specified, shown or directed. Subgrades must be visually inspected to ensure suitable conditions for succeeding work; must be proof rolled and tested for density and moisture content at a minimum frequency of nine (9) tests per acre. Minimum required densities shall be as specified, shown or directed.
3.2.2 A groundwater suppression system shall be placed directly on the prepared subgrade according to the Specification and dimensions shown on the Contract Drawings.
3.2.3 Placing Liner Soils:
3.2.3.1 Place soil liner material to grades and elevations as shown on the Contract Drawings. Frozen material shall not be used.
3.2.3.2 The soil liner material shall be spread systematically in uniform lifts, disk harrowed or worked a uniform consistency, if necessary, and compacted to a maximum lift thickness of approximately eight (8) inches. When placing the first lift of the soil component of the liner system, the thickness may be increased to ensure adequate compaction, attain the required moisture, density and permeability results and protect the underlying subgrade, geotextile or similar element. Any succeeding lifts may be reduced in thickness in order to achieve the overall minimum liner system thickness.
3.2.3.3 Compaction must be performed by properly controlling the moisture content, lift thickness, compactive energy/kneading action to effectively destroy soil clods. Placement operations shall include surface scarification and moisture conditioning as necessary to eliminate lift interfaces. Initial lift compaction must be performed with an Engineer approved padfoot soil compactor with a foot depth of 5-inches or greater. If a static soil compactor is used, it must have a minimum operating weight of 60,000 lbs and have foot depths that do not damage underlying geosynthetics. If a dynamic (vibratory padfoot) compactor is used, it must be capable of applying a minimum compactive force of 55,000 lbs. Compaction and moisture conditioning shall be performed so that the roller effectively “walks out” of the soil lift. Following initial
6.19 02292-4 394.107.001 SECTION 02292
SOIL LINER MATERIAL
compaction, a smooth roller shall be used, as necessary, to seal the lift surface and to accommodate in-place testing.
3.2.3.4 The moisture content of the soil component of the liner system must be maintained (before, during and after compaction) within the range identified by the moisture-density- permeability relationship developed for the material and as may be modified by the Construction Quality Control Test results to ensure that the remolded lift attains a maximum in situ permeability as required.
3.2.3.5 The density of the compaction must be within the range identified by the moisture- density-permeability relationship established for the material and may be modified by the Construction Quality Control Test results to ensure that the remolded lift attains a maximum in situ permeability as required.
3.2.3.6 Secondary soil liner shall be a minimum of 24 inches in compacted thickness and must have a maximum remolded coefficient of permeability of 1 x 10-7 cm/sec (unless otherwise noted) throughout its thickness.
3.2.3.7 At the completion of each day’s work, a smooth drum roller shall be utilized to smooth the soil surface in order to reduce moisture penetration in the event of rain or excessive drying. The surface shall be scarified and moisture conditioned as necessary upon the placement of succeeding lifts.
3.2.3.8 Hand compaction at the proper moisture content shall be employed in all places around liner penetrations and irregular interfaces in order to maintain proper permeability results while protecting geosynthetics and other construction elements.
3.2.3.9 The final compacted surface of the secondary soil liner shall be free of stones greater than one (1) inch, and sub-angular embedded stones protruding more than 3/8-inch above the finished surface. No dry gravelly areas shall be permitted on the surface.
3.2.3.10 Upon completion of each soil liner lift, the surface shall be continuously maintained by positive means such as covering, moisture conditioning, etc., as necessary or directed by the Engineer to prevent drying, cracking and desiccation. If desiccation cracks exceed 1 inch in depth in a particular area, the liner soil shall be repaired by discing the affected area, adding water to the disced soil, rediscing to mix the water into the soil and finally recompacting the area to meet the moisture-density-permeability requirements. If desiccation cracks are greater than 4- 1/2 inches in depth, the entire lift thickness must be re-worked through scarification, moisture conditioning, and recompaction as necessary to remold the entire lift thickness. The width of
6.19 02292-5 394.107.001 SECTION 02292
SOIL LINER MATERIAL
scarification and recompaction shall be centered on the desiccation crack and be equal to or greater than the width of the compactor (not the drum) approved during the test pad construction. If desiccation cracks are less than 1 inch in depth, the soil can be moisture conditioned and smooth drum rolled just prior to placement of the geomembrane. Areas exhibiting loss of fines shall be evaluated to determine if additional material needs to be removed. Any lost or removed material will be replaced with new soil liner material from the stockpiles which will be compacted and tested. All compaction and testing of soil liner repairs will be in accordance with Paragraphs 3.2 and 3.3 of this Section.
3.3 CONSTRUCTION QUALITY CONTROL:
3.3.1 Construction Quality Control procedures shall be conducted to verify that field compaction of the soil liner material has been achieved and that the permeability requirements have been met as established by the Criteria and Acceptance Section of this Specification or as modified by the developed moisture-density-permeability relationship. Should initial Construction Quality Control Tests indicate the constructed liner fails the criteria for acceptance, further testing of remediated work shall be at the expense of the Contractor using the same Construction Quality Control Laboratory which performed the initial testing.
3.3.1.1 The Contractor is responsible for performing all in-place and stockpile soil testing as outlined herein for all soil liner material utilized.
3.3.2 The soil liner material shall be tested from the stockpiled materials prior to placement for the following parameters:
Test Method Frequency
Moisture Content 1,000 cubic yards (ASTM D2216)
Atterberg Limits 1,000 cubic yards (ASTM 4318)
Grain Size Analysis 2,500 cubic yards (ASTM D421 and D422)
Modified Proctor Density 5,000 cubic yards (ASTM D1557)
6.19 02292-6 394.107.001 SECTION 02292
SOIL LINER MATERIAL
In addition, one laboratory permeability test using a triaxial cell with back pressure (D5084) and a minimum of one comparison of the moisture-density-permeability relation for every 5,000 cubic yards to be placed and one for each time soil material changes are noted.
3.3.3 In-place moisture and density testing will be performed in accordance with ASTM D3017 and D2922. Tests will be performed at a frequency of one per 2,500 square feet (18/acre) for each soil liner lift placed. Contractor shall establish a grid system approved by the Engineer to locate test points, Contractor shall establish elevations for each location.
3.3.4 Results of in-place moisture and density tests must be compared to the test pad moisture-density-permeability relationship and other Construction Quality Control Data to ensure the soil liner meets the required performance criteria.
3.3.5 "Undisturbed" Shelby tube samples shall be secured at a rate of one sample per acre per lift at locations chosen by the Engineer and tested for permeability using an approved triaxial permeability test with back pressure. Test results must meet or exceed the criteria for acceptance given below. In addition, a soil sample shall be taken at each Shelby tube location and tested for sieve analysis (ASTM D421 and D422) and moisture content (ASTM D2216).
3.3.6 If permeability testing indicates work does not meet requirements, at least 5 samples shall be obtained in the immediate vicinity of the failed sample along with a visual inspection of the soil liner. At a minimum, the additional testing will be performed at least 25 feet beyond the failed result. These samples shall be tested, the failed area localized and reconstructed in accordance with these Specifications and retested. This work shall be done at no cost to the Owner under the direction of the Engineer.
3.3.7 All holes caused by Shelby tube sampling will be properly filled with powdered bentonite followed by tamping the material. All sample locations will be tested to verify density and moisture content. All soil liner perforations resulting from in-place moisture density testing (nuclear density testing) shall be properly filled with powdered bentonite.
3.4 CRITERIA FOR ACCEPTANCE:
3.4.1 Criteria of the in-place soil liner are as follows unless modified by test pad Inference Data or stockpile Construction Quality Control Test results:
- Compaction - a minimum of 90% (or greater as determined by the moisture-density- permeability relationship or other Construction Quality Control Tests) of the maximum dry density as determined by the Modified Proctor Test (ASTM D1557) at
6.19 02292-7 394.107.001 SECTION 02292
SOIL LINER MATERIAL
or above the optimum moisture content necessary to achieve the required permeability results as follows:
- Coefficient of Permeability - a maximum of 1 x 10-7 cm/sec. for all secondary soil liner lifts.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - SOIL LINER MATERIAL:
4.1.1 Measurement of the quantity of Soil Liner Material, allowed for payment, shall be computed, after compaction, by using the product of the length, depth as directed, and the actual width, but not to exceed the established lines as shown on the drawings or as directed by the Engineer, less the volume occupied by any pipe or structures, if any.
4.2 PAYMENT - SOIL LINER MATERIAL:
4.2.1 For Soil Liner Material, not included in other unit or lump sum price items, payment for Soil Liner Material will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 02292-8 394.107.001 SECTION 02376
EROSION CONTROL BLANKETS
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Erosion Control Blankets as shown on the Plans, as specified, and/or directed.
1.2 SUBMITTALS:
1.2.1 The Contractor shall submit six (6) copies of the manufacturer’s material specifications for each item to be supplied under this Section.
1.3 DELIVERY, HANDLING AND STORAGE:
1.3.1 The Contractor will be liable for all damages to the materials incurred prior to and during transportation to the site.
1.3.2 Handling, storage and care of materials prior to and following installation at the site is the responsibility of the Contractor. Erosion control blankets shall be properly stored by the Contractor at the site according to the manufacturer’s recommendations. Any blankets damaged during storage shall be replaced at the Contractor’s expense.
PART 2 - PRODUCTS
2.1 MATERIALS:
2.1.1 Seed and Fertilizer: Seed and fertilizer shall be provided and installed as outlined in Section 02485.
2.1.2 Erosion Control Blankets:
2.1.2.1 The erosion control blanket shall be a machine-produced mat of 70% agricultural straw and 30% coconut fiber matrix. The blanket shall be of consistent thickness with the straw and coconut fiber evenly distributed over the entire area of the mat. The blanket shall be covered on the top side with heavyweight photodegradable netting having ultraviolet additives to delay breakdown and an approximately 0.63-inch x 0.63-inch mesh. The bottom side shall be covered with a lightweight photodegradable polypropylene netting having an approximate 1/2-inch x 1/2- inch mesh. The blanket shall be sewn together on 1.5-inch centers with degradable thread.
6.19 02376-1 394.107.001 SECTION 02376
EROSION CONTROL BLANKETS
2.1.2.2 The erosion control blankets shall be SC150 as manufactured by North American Green, or equivalent. The erosion control blanket shall have the following material content:
Matrix - 70% Straw Fiber (0.35 lbs/sy) 30% Coconut Fiber (0.15 lb/sy)
Netting - Top: Heavyweight photodegradable with UV additives (3.0 lbs/1,000 sf) Bottom: Lightweight photodegradable (1.64 lbs/1,000 sf)
Thread - Degradable
2.1.2.3 The functional longevity of the erosion control blanket shall be approximately 24 months.
2.1.2.4 The blankets shall be manufactured with a colored line or thread stitched along both outer edges (approximately 2 – 5 inches from the edge) to ensure proper material overlapping.
2.1.2.5 All erosion control blankets shall be properly stored by the Contractor at the site per manufacturer’s recommendations. Any blankets damaged during storage shall be replaced at the Contractor’s expense.
PART 3 - EXECUTION
3.1 INSTALLATION:
3.1.1 The erosion control blankets shall be installed as indicated on the Contract Drawings and/or directed. Conventional straw mulch shall not be installed where erosion control blankets are to be placed. Erosion control blankets can be installed directly over hydroseeded areas.
3.1.2 At the top of the slope, the blanket shall be anchored in a 6-inch deep x 6-inch wide trench. Backfilling and compaction of the trench shall be performed shortly after stapling the blanket in the trench.
3.1.3 Blankets shall be installed either down or horizontally across the slope. Edges of parallel blankets must be stapled with a minimum 3-inch overlap. When blankets are spliced down the slope, shingle the blankets with a minimum 6-inch overlap.
6.19 02376-2 394.107.001 SECTION 02376
EROSION CONTROL BLANKETS
3.1.4 Staples shall be 6-inch wire staples, or approved equal. Staples shall be applied at a minimum of 1 staple per square yard on the blankets and a maximum of 12-inches apart on all overlap areas and in anchor trenches.
3.2 MAINTENANCE AND PROTECTION:
3.2.1 The Contractor shall maintain and protect all erosion control blankets until final acceptance of the Contract.
3.2.2 If any staples become loosened or raised, or if any blankets become loose, torn or undermined, the Contractor shall make repairs immediately to the satisfaction of the Engineer.
3.2.3 Level and grade to the extent required to present a sightly appearance and to prevent any obstruction of the flow of water or any other interference with operation of or access to the permanent works.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT – EROSION CONTROL BLANKETS:
4.1.1 The quantity for which payment will be made shall be the actual number of acres covered.
4.2 PAYMENT – EROSION CONTROL BLANKETS:
4.2.1 For Erosion Control Blankets, not included in other unit or lump sum price items, payment for Erosion Control Blankets will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 02376-3 394.107.001 SECTION 02484
TOPSOIL
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Topsoil as shown on the Plans, as specified, and/or directed.
PART 2 - PRODUCTS
2.1 MATERIAL:
2.1.1 Topsoil shall be utilized from on-site sources as directed by the Engineer and outlined in the Contract Documents. Estimated topsoil removal in all areas is approximately 8 inches. Contractor shall verify prior to bidding.
2.1.2 Topsoil shall not be delivered or placed in a frozen or muddy condition. The material shall contain no objects greater than two inches in greatest dimension.
2.1.3 Contractor to condition topsoil as necessary. Topsoil shall have an acidity range of pH 5.0 to 7.0 and shall contain 2 to 20% organic matter as determined by loss of ignition of moisture-free samples dried at 100 degrees C.
1. Where topsoil pH is below 5.0, lime shall be added at a rate of 2-1/2 lbs. per cubic yard of topsoil to raise the pH value one full point.
2. Where topsoil pH is above 7.0, aluminum sulfate shall be added at a rate of 2-1/2 lbs. per cubic yard of topsoil to lower the pH value one full point.
2.2 SOIL AMENDMENTS:
2.2.1 Lime: Natural dolomitic limestone containing not less than 85 percent of total carbonates with a minimum of 30 percent magnesium carbonates, ground so that not less than 90 percent passes a 10-mesh sieve and not less than 50 percent passes a 100-mesh sieve.
2.2.2 Aluminum Sulfate: Commercial grade, in dry powder form.
2.3 SUBMITTALS:
6.19 02484-1 394.107.001 SECTION 02484
TOPSOIL
2.3.1 The Contractor shall submit six (6) copies of a pH test and organic content test for the Engineer=s review for the topsoil to be used. PART 3 - EXECUTION
3.1 QUALITY ASSURANCE
3.1.1 Topsoil will be visually inspected upon delivery and material that does not comply with the Specification will be rejected. If a noticeable change in topsoil quality is identified by the Engineer, the Contractor shall perform additional pH and organic content tests of the new material at no additional cost to the Owner.
3.2 PLACING:
3.2.1 Topsoil shall include fine grading the surface of the ground upon which topsoil is to be placed and the furnishing and placing of topsoil in the areas to be seeded or planted.
3.2.2 Depth of topsoil shall be minimum 4 inches unless otherwise shown or directed.
3.2.3 After approval by the Engineer of the fine grading of the subgrade, the topsoil shall be spread and compacted with a light roller to the lines, grades and elevations shown on the drawings, or directed by the Engineer, without unsightly variations, ridges or other depressions which will hold water. Any stone, litter or objectionable material shall be removed from the topsoil and the surface raked to true lines. Any uneven spots shall be leveled. The work shall not be performed during unsuitable weather.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - TOPSOIL:
4.1.1 The quantity of Topsoil for which payment will be made will be the plan view in square feet at the depths specified (4 inches unless otherwise noted) covered by topsoil. This area shall be determined based on as-built drawings of the topsoil area supplied by a NYS licensed surveyor hired by the Contractor.
6.19 02484-2 394.107.001 SECTION 02484
TOPSOIL
4.2 PAYMENT - TOPSOIL:
4.2.1 For Topsoil, not included in other unit or lump sum price items, payment for Topsoil will be made at the applicable price stated in the Bid and shall cover all costs and expense incidental to excavating from storage, transporting, rehandling and placing in the completed work as shown, specified and directed. No payment will be made for any portion of this item until the Topsoil has been placed in final location.
END OF SECTION
6.19 02484-3 394.107.001 SECTION 02485
SEEDING
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Seeding as shown on the Plans, as specified, and/or directed.
1.1.2 The Contractor shall seed new areas and disturbed areas where shown on the Drawings, specified or directed by the Engineer. Contractor shall prepare the seed bed by scarifying or otherwise loosening soil to a depth of 2 inches, applying fertilizer, lime, seed and mulch at the rates specified.
1.1.3 Topsoil shall be applied to exterior slopes of the containment berms, stockpiles, and other site areas to be restored, and prepared as outlined in Section 02484.
1.2 SUBMITTALS: The Contractor shall submit six (6) copies of the proposed seed mixture and fertilizer for the Engineer’s review and approval.
PART 2 - PRODUCTS
2.1 MATERIALS:
2.1.1 Fertilizer:
2.1.1.1 Commercial fertilizer (30-0-04) shall contain not less than thirty percent nitrogen, and four percent water soluble potash. The fertilizer shall be inorganic or a combination of inorganic and organic substances. The fertilizer shall not have a phosphate content of more than 0.6% phosphorus by weight.
2.1.1.2 If, as an alternative, the Contractor wishes to substitute another fertilizer he may do so with the approval of the Engineer, and the rate of fertilizer to be used shall be whatever amount is required to furnish the same amount of nitrogen as would be supplied by the specified fertilizer.
2.1.1.3 Commercial fertilizer shall be delivered in original bags of the manufacturer, showing weight, analysis and the name of the manufacturer.
6.19 02485-1 394.107.001 SECTION 02485
SEEDING
2.1.1.4 If the commercial fertilizer is not used immediately after delivery, the Contractor shall store it in such a manner that its effectiveness will not be impaired.
2.1.2 Seed:
2.1.2.1 Grass seed shall be a mixture of the species and/or varieties specified, mixed in the proportions specified.
2.1.2.2 The seed shall be fresh, recleaned and of the latest crop year. It shall conform to Federal and State Standards. Each type of grass in the mixture shall meet or exceed the minimum percentage purity and germination listed for that type of grass.
2.1.2.3 The following seed mixture shall be used for ditches, slopes and all areas disturbed by construction.
Percentage Species or Percent by Weight Variety Germination 30 Kentucky 31 Tall Fescue 85% 30 Perennial Ryegrass 85% 20 New Zealand White Clover 85% 20 Creeping Red Fescue 85%
2.1.2.4 No Reed Canary Grass shall be allowed in any areas of the site.
2.1.2.5 The balance of material in an acceptable seed mixture, other than specified pure live seed shall, for the most part consist of non-viable seed, chaff, hulls, live seeds of crop plants and harmless inert matter. The percentage of weed shall not exceed one percent by weight for the mixture.
2.1.2.6 All seed mixtures furnished under this Item shall be mixed by the vendor and shall be delivered in standard sized bags of the vendor, showing the weight, analysis and vendor's name.
2.1.2.7 All seed shall be properly stored by the Contractor at the site of the work and any seed damaged during storage shall be replaced.
2.1.3 Mulch:
2.1.3.1 Straw or hay mulch shall consist of oats, wheat, rye or other approved crops which are free of noxious weeds. Weight shall be calculated on the basis of the straw having not more than 15% of moisture content.
6.19 02485-2 394.107.001 SECTION 02485
SEEDING
PART 3 - EXECUTION
3.1 INSTALLATION:
3.1.1 Time For Seeding:
3.1.1.1 All seeding shall be done in a dry or moderately dry soil and at times when the wind does not exceed a velocity of five miles per hour.
3.1.1.2 Temporary Seeding: Temporary seeding shall be completed by the Contractor to minimize exposed soils and stabilize areas prior to final seeding. At all times the Contractor shall maintain a supply of seed and mulch on-site to stabilize all exposed areas.
3.1.2 Preparation of Seed Bed:
3.1.2.1 After the finished grading is completed and just before seeding, the areas to be seeded shall be loosened to a depth of two inches and free from depressions which will hold water. All sticks, stones, clods, roots or other objectionable material which might interfere with the formation of a fine seed bed shall be removed from the soil.
3.1.2.2 Commercial fertilizer shall be evenly applied at the rate of 300 pounds per acre.
3.1.3 Seeding:
3.1.3.1 Grass seed mixture shall be sown at the rate of 200 pounds per acre.
3.1.3.2 The seed shall be sown by hydroseeding in such a manner that a uniform stand will result.
3.1.3.3 The Contractor shall mix water, seed fertilizer, mulch and mulch anchorage at the following rates and apply to the prepared seed bed by means of a hand-held hose. No truck mounted spraying equipment shall be driven over the areas to be seeded. Discharge shall be in an uphill direction only.
6.19 02485-3 394.107.001 SECTION 02485
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a. Fertilizer - 300 lbs. per acre b. Seed - 250 lbs. per acre c. Mulch - Sufficient to equal 90% straw mulch coverage d. Mulch Anchorage - Per manufacturer's instructions Chemical 750 lbs. wood fiber/acre Wood Cellulose
3.1.3.4 Where the mulch anchorage is provided ready mixed with the mulch, no additional mulch anchorage will be required.
3.1.3.5 Mulch shall be a commercial cellulose hydromulch such as "Conwed 2000", "Turf Fiber", or equal. Soil seal or mulch anchorage used shall be approved by the Engineer. An asphalt emulsion shall not be used as mulch anchorage.
3.1.4 Mulching:
3.1.4.1 Within three days after hydroseeding, the seeded areas shall be covered with a supplemental uniform blanket of straw or hay mulch at the rate of 1,000 pounds per acre of seeded area or as required to provide 90% coverage (i.e., lightly cover 90% of the surface).
3.2 MAINTENANCE AND PROTECTION:
3.2.1 The Contractor shall maintain and protect all seeded areas until final acceptance of the Seeding portion of the Contract.
3.2.2 Final acceptance will not be made until an acceptable uniform stand of grass is obtained in all newly seeded areas except that the Engineer at his discretion may accept a portion or portions of the work at various times.
3.2.3 Upon final acceptance of a seeded area by the Engineer, the Owner will assume responsibility for maintenance and protection of that area.
3.2.4 Any portions of seeded areas which are unacceptable, and which fail to show a uniform stand of grass from any cause, shall be reseeded as before except the fertilizer shall be applied at one-half the original rate. The seeding shall be repeated until the seeded areas are satisfactorily covered with grass.
6.19 02485-4 394.107.001 SECTION 02485
SEEDING
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - SEEDING:
4.1.1 The quantity for Seeding which payment will be made shall be the actual number of acres covered.
4.2 PAYMENT - SEEDING:
4.2.1 For Seeding, not included in other unit or lump sum price items, payment for Seeding will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 02485-5 394.107.001 SECTION 02593
REINFORCED POLYETHYLENE (POLY) COVERING
PART 1 – GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Reinforced Polyethylene (Poly) Covering as shown on the Plans, as specified and/or directed.
1.1.2 The reinforced poly covering shall be a scrimmed geomembrane with a nominal thickness of 12 mils. The material shall consist of two sheets of high strength polyethylene film laminated together with a third layer of molten polyethylene. The material shall provide long term (2 years +) water retention while being exposed outdoors.
1.1.3 The reinforced poly covering will be used as the surface water infiltration barrier over the primary leachate collection layer and on the stormwater diversion berms as shown on the Contract Drawings.
1.2 SUBMITTALS:
1.2.1 Prior to installation and delivery of the poly covering, the Contractor shall submit to the Engineer, from the material manufacturer, a description of the material, long-term exposure characteristics and guaranteed properties of the poly covering as outlined in Part 2 of this Section. The Contractor shall provide the Engineer, from the material manufacturer, a written certification stating that the materials meet or exceed the guaranteed properties submitted.
1.2.2 All required quality control documentation of the specific material lots dedicated for this project will be certified and signed by the Quality Control Manager at the manufacturing plant. This information will be submitted to the Engineer for approval at no additional expense to the Owner.
1.2.3 Prior to delivery and installation of the material, the Contractor shall submit the Engineer for review and approval a proposed panel layout for the ploy covering. The ploy covering shall be manufactured in the largest possible panel sizes to minimize field seaming.
1.2.4 The Contractor shall submit to the Engineer for approval manufacturer’s information on the sandbags to be used as permanent ballasts.
6.19 02593-1 394.107.001 SECTION 02593
REINFORCED POLYETHYLENE (POLY) COVERING
PART 2 – PRODUCT
2.1 MATERIALS:
2.1.1 The poly covering shall be a multi-layered reinforced laminate, which contains no adhesives. The outer layers shall consist of a high strength polyethylene film that contains U.V. and thermal stabilizers which allows the material to be exposed outdoors for a minimum of 2 years without losing strength and water retention characteristics.
2.1.2 The poly covering shall be reinforced with denier polyester scrim laid in a diagonal pattern with an additional machine direction scrim. The individual plys shall be laminated together with molten polyethylene.
2.1.3 The Poly Covering shall be manufactured in the largest possible panel sizes in order to minimize field seams. The poly covering shall be made by Raven Industries (Dura-Shrim 12BBR), or approved equal.
2.2 REINFORCED POLY COVERING MINIMUM SPECIFICATIONS:
Property Specification Limit Test Method
Thickness, Nominal +/- 12 mil
Weight per MSF 60 lbs.
1” Tensile Strength 59 lbf. ASTM D751
Elongation @ Break 650% ASTM D751
Grab Tensile 90 lbf ASTM D751
Trapezoid Tear 72 lbf ASTM D4533
Hydrostatic Resistance 100 psi ASTM D751
Max/Min Temperature 180oF / -70oF
Perm Rating 0.051 US Perms ASTM E96, Method A
WVTR 0.023 g/110in2/day ASTM E96, Method A
6.19 02593-2 394.107.001 SECTION 02593
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2.2 DELIVERY, HANDLING AND STORAGE:
2.2.1 The Contractor will be liable for all damages to the materials incurred prior to and during transportation to the site.
2.2.2 Handling, storage and care of the materials prior to and during installation is the responsibility of the Contractor until final acceptance by the Owner. The material shall be stored off the ground on pallets or other suitable techniques.
2.2.3 Labels on each factory roll/panel will identify:
• The thickness of the material • The length and width of the roll • The manufacturer • Product identification • Lot number • Roll or field panel number
PART 3 - EXECUTION
3.1 POLY COVERING INSTALLATION:
3.1.1 Placement of the panels in the field will be according to the Plans, the approved panel layout and/or directed by the Engineer. Placement will follow all instructions on the boxes or wrappings containing the material which describe the proper methods of unrolling, and/or unfolding rolls and panels.
3.1.2 The panels shall be placed to minimize seams especially where water is expected to be retained. Seam locations are to be approved by the Engineer in accordance with the approved panel layout.
3.1.3 The method of placement must ensure that:
3.1.3.1 No equipment used will damage the material by handling, trafficking, leakage of hydrocarbons, or other means.
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3.1.3.2 No personnel working on or with the material will smoke, wear damaging shoes, or engage in other activities which could damage the poly covering.
3.1.3.3 Adequate temporary loading and/or anchoring (e.g., sand bags), not likely to damage the material, will be placed to prevent uplift by the wind (in case of high winds, continuous loading is recommended along the edges of the panels to minimize risk of wind flow under the panels).
3.1.4 The material shall be deployed to lay as flat as possible. Excessive wrinkling shall be avoided. The final deployment surface shall be uniform and free of sharp objects.
3.1.5 Seaming: When deploying multiple panels, the additional panels should be deployed and positioned with a minimum 4’-6” overlap. The panels shall be sewn together using a “J” fold sewn seam. Sewing shall be by mechanical means using manufacturer approved thread.
3.1.6 Permanent Ballasting: Following deployment, the poly covering shall be permanently ballasted using long life sands recommended by the manufacturer. Sandbags shall have a life equal to or greater than the poly covering material. Sandbags shall be placed approximately 10-feet on center in all directions and at the toe of slopes. At the termination free ends, sandbags shall be placed end to end. When placing sandbags on slopes, the sand bags shall be tied together using rope. Additional bags shall be placed continuously at toes of diversion berms and low points.
3.1.7 Any damage to the material panels or portions of the panels as a result of storage or placement must be replaced or repaired at no additional cost to the Owner. The decision to replace or repair any panel or portions of panels will be made by the Engineer.
PART 4 – MEASUREMENT & PAYMENT
4.1 MEASUREMENT – REINFORCED POLYETHYLENE (POLY) COVERING:
4.1.1 Measurement of the quantity of Reinforced Polyethylene (Poly) Covering allowed for payment shall be based on the number of square feet placed to the nearest one foot of material placed less the area of overlap in accordance with the Specifications, Plans or as approved by the Engineer.
6.19 02593-4 394.107.001 SECTION 02593
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4.2 PAYMENT – REINFORCED POLYETHYLENE (POLY) COVERING:
4.2.1 Unit Pricing For Temporary Installations: The Contractor shall provide unit pricing for temporary installation and removal of the poly covering if requested by the Owner for stormwater management.
4.2.2 For the Reinforced Polyethylene (Poly) Covering, not included in other unit or lump sum price items, payment for Reinforced Polyethylene (Poly) Covering will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 02593-5 394.107.001 SECTION 02594
LINER SYSTEM PERFORMANCE TESTING
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment to perform liner system performance testing on the completed double composite liner system as outlined herein.
1.1.2 The Contractor is responsible to construct the liner system so the resulting primary liner system leakage rate is below allowable leakage rate of 20 gallons per acre per day (gpad) as set forth in 6NYCRR Part 360 Regulations for Solid Waste Management Facilities based on a 30 day average (6NYCRR Part 363-6.19(d)).
1.1.3 If the measured primary liner system leakage rate is above the allowable leakage rate as outlined above, the Contractor is responsible for investigating the cause of the excessive secondary leachate collection system flows and to report to the Engineer, in writing, within 5 days. Upon identifying the cause, the Contractor is responsible for repairing the liner system to the satisfaction of the Engineer at no additional cost to the Owner. After repairs, monitoring of the secondary leachate collection system flows will resume until a 30 day average below 20 gpad is achieved. Substantial completion will not be granted until the 30 day average is below 20 gpad.
1.1.4 Following installation of the overlying soil drainage layers, the Contractor shall perform a leak location survey of both the secondary and primary geomembranes for areas where the slope is less than 10 percent. The Contractor shall make any and all repairs necessary as described herein.
PART 2 - PRODUCTS
NOT USED
PART 3 - EXECUTION
3.1 LINER SYSTEM:
3.1.1 The secondary liner system flows for Cell Nos. 12 and 13 will be measured by the Contractor at the proposed Cell No. 12 and Cell No. 13 sideriser buildings, respectively. Flows
6.19 02594-1 394.107.001 SECTION 02594
LINER SYSTEM PERFORMANCE TESTING
will be recorded daily in accordance with 6NYCRR Part 360 Regulations and the facility’s operating permit. The Engineer shall be present for all readings.
3.1.2 Primary liner system leakage rate monitoring can commence once the HDPE geomembrane of the primary liner system is completely installed and all test results, both destructive and non-destructive, are received and accepted by the Engineer. However, at least fifteen (15) days of monitoring must be performed after the completion of the primary leachate collection layer.
3.1.3 Construction of the primary leachate collection can be on-going while monitoring the secondary leachate collection system flows.
3.1.4 At a minimum, leakage rates should be tested by two (2) rain events of 0.5 inch or more or a total of 1 inch of rain within the required testing timeframe. If no precipitation is foreseen, clean water can be pumped into the cell to represent precipitation events by a method approved by the Engineer.
3.2 LEAK LOCATION SURVEY: A secondary geomembrane leak location survey shall be performed by the Contractor following the installation of the secondary composite geonet and completion of the structural fill layer. A primary geomembrane leak location survey shall be performed by the Engineer following the completion of the primary collection stone. The leak location survey shall use an electrical method described in ASTM D7007 and be completed by a surveyor with successful experience in large-scale leak location surveys for geomembranes covered with soil including surveys within the previous three years totaling at least 10,000,000 square feet. Information demonstrating the surveyor’s experience shall be submitted to the Engineer for review and approval prior to commencement of the leak location surveys.
3.2.1 The secondary geomembrane survey will be performed prior to the installation of the primary geosynthetic clay liner (GCL) following the installation of the structural fill layer. The area to be surveyed includes the entire surface area of secondary geomembrane as outlined below.
a. A survey of the entire secondary geomembrane floor surface area, including all areas with slopes less than 10%, shall be performed after structural fill placement and fine grading.
3.2.2 The primary geomembrane survey will be performed during the 30-day primary liner system leakage rate monitoring period. The area to be surveyed includes the entire surface area of the primary geomembrane as outlined below.
6.19 02594-2 394.107.001 SECTION 02594
LINER SYSTEM PERFORMANCE TESTING
a. A survey of the entire primary geomembrane floor surface area, including all areas where the GCL is directly beneath the primary geomembrane, shall be performed after primary collection layer stone placement (Type A and B Select Fill) and fine grading.
3.2.3 The Contractor shall prepare the liner system for the survey as necessary to achieve the specified leak detection sensitivity at no additional cost to the Owner. Leaks must have moisture in them during the survey. The Contractor shall be responsible for wetting the test area as necessary and to provide a generator for the Engineer’s use at no additional cost to the Owner.
3.2.4 The leak detection sensitivity shall be demonstrated and documented to the satisfaction of the Engineer under trial test conditions using an artificial leak. The operation of the system and survey parameters shall be shown to be capable of detecting a 0.25-inch diameter leak in the secondary and primary geomembranes under the leachate collection layers. This capability must be demonstrated under worst-case measurement spacing conditions. It will not be sufficient to merely detect an artificial leak of the specified size by making measurements near the leak. The measurements must be made with measurement spacings the same as that for the actual production survey, with the sensor probe passing the worst-case distance from the leak.
3.2.5 The leak location data shall be taken at positions or scan distances spaced no farther apart than that used for the trial tests. For the surveys, data shall be recorded, plotted, and analyzed for leak signals. The positions of these leak signals shall be located and the leaks excavated. All leaks shall be repaired. Electrical isolation of individual leaks will be necessary to ensure no additional leaks are in the surrounding area. The leak location survey shall be repeated on the two closest survey lines for a distance extending 20 feet before and beyond the leak. If another leak signal is detected, this process shall be repeated until no additional leaks are detected.
3.2.6 Any leaks discovered during the survey process shall be hand excavated and repaired by the Contractor at no additional cost to the Owner. Upon repairing a leak, the repair shall be non-destructively tested in accordance with Section 02596. Once the geomembrane is successfully repaired, the overlying layers shall be replaced at no additional cost to the Owner.
3.2.7 The daily results of the work shall be communicated to the Engineer. A report documenting the electrical leak location surveys shall be submitted to the Engineer by the Contractor within 14 days of the completion of each leak location survey. The reports shall document the methodology used, the locations and descriptions of the leaks, a voltage map with measurement spacings, photographs of any leaks, and a diagram of the survey area showing the
6.19 02594-3 394.107.001 SECTION 02594
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approximate leak locations. All leak locations shall be surveyed by the Contractor to be included in the final secondary and primary geomembrane as-built drawings.
3.2.8 The Contractor shall incorporate the leak location survey into the construction schedule. The Contractor shall be responsible for coordinating the schedule with the Engineer to ensure minimal delays. Any delays resulting from a failure to coordinate with Engineer shall be the sole responsibility of the Contractor.
PART 4 - MEASUREMENT AND PAYMENT
4.1 MEASUREMENT - LINER SYSTEM PERFORMANCE TESTING:
4.1.1 Measurement for Liner System Performance Testing shall include the cost of all material, equipment and labor required for the work indicated in this Section.
4.2 PAYMENT - LINER SYSTEM PERFORMANCE TESTING:
4.2.1 For Liner System Performance Testing, not included in other unit or lump sum price items, payment will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 02594-4 394.107.001 SECTION 02596
HIGH DENSITY POLYETHYLENE (HDPE) LINING MATERIAL
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for High Density Polyethylene (HDPE) Lining Material as shown on the Plans, as specified and/or directed.
1.1.2 The lining material will be used as the upper lining component of each composite liner in a double liner system.
1.1.3 The lining material will be textured on both sides for all applications and have smooth edges to better accommodate hot wedge welding.
1.2 REFERENCES:
1.2.1 Geosynthetic Research Institute, GM13 “Test Properties, Testing Frequency and Recommended Warranty for High Density Polyethylene (HDPE) Smooth and Textured Geomembranes”, Revision 16, January 6, 2016.
1.3 PRE-QUALIFICATIONS:
1.3.1 Geomembrane Manufacturer:
1.3.1.1 The Contractor shall submit to the Owner and the Engineer for approval the following qualification information regarding the Geomembrane Manufacturer:
a. Corporate background and information.
b. Manufacturing capabilities including:
- daily production quantity available for this Contract - quality control procedures for manufacturing - list of material properties including certified test results, to which geomembrane samples are attached.
c. A list of at least ten completed facilities, totaling a minimum of 10,000,000 square feet, for which the Manufacturer has manufactured a geomembrane. For each facility, the following information will be provided:
2.19 02596-1 394.107.001 SECTION 02596
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- name and purpose of facility, its location and date of installation - name of Owner, Project Manager, Designer, Fabricator (if any), and Installer - thickness of geomembrane, surface area of geomembrane manufactured - available information on the performance of the lining system and the facility.
d. Origin (resin supplier's name, resin production plan) and identification (brand name, number) of the resin.
1.3.2 Geomembrane Fabricator (if required):
1.3.2.1 The Contractor shall submit to the Engineer for approval the following written information in regards to the Geomembrane Fabricator (if required).
a. Copy of Geomembrane Manufacturer's letter of approval of license.
b. Corporate background and information.
c. Fabrication Capabilities:
- daily fabrication quantity available for this Contract - quality control procedure - samples of fabricated seams and a certified list of minimum values of seam properties and employed test methods.
d. A list of at least ten completed facilities for which the Fabricator has fabricated liner factory panels of the type of geomembrane to be used in this project, totaling a minimum of 3,000,000 square feet, the following information will be provided for each fabrication:
- name and purpose of facility, its location, and date of installation - name of Owner, Project Manager, Designer, Manufacturer, Installer, and the name of the contact at the site who can discuss the project - thickness of liner and surface area of liner fabricated - type of seaming and type of seaming apparatus used - available information on the performance of the lining system and the facility.
1.3.3 Installer:
1.3.3.1 The Installer must be trained and qualified to install geomembrane and must be approved and/or licensed by the Geomembrane Manufacturer and/or Fabricator.
2.19 02596-2 394.107.001 SECTION 02596
HIGH DENSITY POLYETHYLENE (HDPE) LINING MATERIAL
1.3.3.2 The Contractor shall submit to the Engineer for approval the following written information, relative to the Installer.
a. Copy of Installer's letter of approval or license by the Manufacturer and/or Fabricator.
b. Corporate background and information.
c. Description of installation capabilities, including: - information on equipment and personnel - average daily production anticipated - quality control procedures.
d. A list of at least ten completed facilities, totaling a minimum of 3,000,000 square feet for which the Installer has installed geomembrane of the type for this project. For each installation, the following information will be provided: - name and purpose of facility, its location and date of installation - name of Owner, Designer, Manufacturer, Fabricator (if any), and name of contact at the facility who can discuss the project - name and qualifications of the supervisor(s) of the Installer's crew(s) - thickness of geomembrane and surface area of the installed liner - type of seaming and type of seaming apparatus used - duration of installation - available information on the performance of the lining system and the facility.
e. Resume of the "master seamer" to be assigned to this project, including dates and duration of employment.
f. Resume of the field engineer or installation supervisor to be assigned to this project, including dates and duration of employment.
1.3.3.3 All personnel performing seaming operations will be qualified by experience or by successfully passing seaming tests. At least one seamer will have experience seaming a minimum of 3,000,000 square feet of geomembrane of the type for this project, using the same type of seaming apparatus in use at the site.
1.3.4 Sheet Quality:
1.3.4.1 The Contractor shall submit to the Engineer the following information regarding sheet quality and properties.
2.19 02596-3 394.107.001 SECTION 02596
HIGH DENSITY POLYETHYLENE (HDPE) LINING MATERIAL
a. A material properties sheet including, at a minimum, all specified properties, measured using test methods indicated in the specifications at the frequencies shown (Section 2.1.2), or equivalent.
b. Complete stress rupture curve (Geosynthetic Research Institute, GM5) for test specimen.
c. A list and description of materials other than the base polymer which comprise the geomembrane.
d. A written certification that property values given in the properties sheet are guaranteed by the Geomembrane Manufacturer.
1.3.5 Roll Quality:
1.3.5.1 Prior to shipment, the Contractor will provide the Engineer with a quality control certificate for each roll of geomembrane provided. The quality control certificate will be signed by a responsible party employed by the Geomembrane Manufacturer, such as the Production Manager. The Quality Control Certificate will include:
a. Roll numbers and identification.
b. Documentation certifying the geomembrane was continuously inspected for uniformity, damage, imperfections, holes, cracks, thin spots, foreign materials, tears, punctures and blisters.
c. Sampling results of quality control tests; as a minimum, results will be given for thickness, tensile strength, tear resistance and seam strength evaluated in accordance with the methods indicated in the specifications or equivalent methods approved by the Engineer.
1.3.6 Prior to delivery of material, the Contractor shall submit a sample of the warranty to be provided as described in paragraph 3.2.3.
1.4 DELIVERY, HANDLING AND STORAGE:
1.4.1 The Contractor will be liable for all damages to the materials incurred prior to and during transportation to the site.
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1.4.2 Handling, storage and care of the geosynthetic materials prior to and following installation at the site, is the responsibility of the Contractor. The Contractor will be liable for all damages to the materials incurred prior to final acceptance of the lining system by the Owner.
1.4.3 The Contractor shall notify the Owner of the anticipated delivery time.
1.5 CONFORMANCE TESTING:
1.5.1 Within one week of delivery of the geomembrane, and at the Engineer's direction, the Contractor shall provide the necessary labor, tools and equipment to obtain samples of the geomembrane at the specified frequency for forwarding to the approved testing laboratory for testing at the Contractor's expense to ensure conformance to both the design specifications and the list of guaranteed properties.
1.5.2 As a minimum, tests to determine the following characteristics will be performed on geomembranes:
a. density, ASTM D792/D1505 b. carbon black content, ASTM D4218 c. asperity height, ASTM D7466 d. thickness, ASTM D5994 e. tensile properties, ASTM D6693 f. interface friction testing according to Section 02599
1.5.3 Geomembrane samples will be taken across the entire width of the roll. Unless otherwise specified, samples will be 2.0 feet long by the roll width. The Engineer will mark the machine direction on the samples with an arrow.
1.5.4 Unless otherwise specified, geomembrane samples will be taken at a maximum rate of one per 100,000 square feet.
1.5.5 For each lot number of geomembrane material that arrives at the site, a sample shall be taken by the Contractor and provided to the Owner for archiving. This sample shall be 3.0 feet long by the width of the roll.
1.5.6 The Engineer may approve conformance samples taken at the manufacturing facility. If the Contractor elects to take conformance samples at the manufacturer’s facility rather than on- site in the presence of the Engineer, the Contractor shall provide chain-of-custody forms from the sampling location to the independent laboratory to the site. All conformance test results shall
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be submitted a minimum of seven days prior to installation. No materials shall be installed until acceptable test results are approved by the Engineer.
1.6 WARRANTY:
1.6.1 The Contractor shall submit a draft copy of the warranty to be provided upon completion of the project. The warranty shall meet the requirements of Article 3.2.3 of this Specification.
1.7 ADDITIONAL SUBMITTALS:
1.7.1 The Contractor shall submit detailed shop drawings for the installation of the HDPE material. Shop drawings shall contain all necessary panel layouts, details, dimensions, penetration fabrications, etc., sufficient to assure that fabrication shall meet the intended use and will conform to the geometry of its intended application.
PART 2 - PRODUCTS
2.1 MATERIALS:
2.1.1 Raw Materials:
2.1.1.1 Prior to installation of any geomembrane material, the Contractor shall submit to the Engineer the following information regarding resin quality.
a. A copy of the Quality Control Certificates issued by the Resin supplier. b. Reports on the tests conducted by the Manufacturer to verify the quality of the resin used to manufacture the geomembrane rolls assigned to the considered facility. These tests should include for HDPE resins, density, percent carbon black and percent carbon dispersion according to the methods outlined in this section. c. A statement of origin and identification of raw materials used. d. Documentation demonstrating the chemical compatibility of the materials to withstand leachate generated by municipal solid waste.
2.1.2 HDPE Geomembrane Specifications:
2.1.2.1 HDPE liner material shall meet the Specification values listed below:
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HIGH DENSITY POLYETHYLENE (HDPE) LINING MATERIAL
TEXTURED HDPE GEOMEMBRANE PROPERTIES AND MANUFACTURER'S MINIMUM TESTING FREQUENCIES PROPERTY TEST METHOD VALUE UNITS TESTING FREQUENCY Thickness (min. average nom. -5%)* ASTM D5994 60 mils per roll Lowest individual for 8 out of 10 values -10% Lowest individual for any of 10 values -15% *The manufacturer shall supply 10 values used to calculate the average roll thickness. Asperity Height (min average) (1) ASTM D7466 16 mils every 2nd roll (1) Density (min average) ASTM D1505 / 0.940 g/cc 200,000 lbs D792 Tensile Properties (min. average)(3) ASTM D6693, 20,000 lbs Type IV Yield Strength: 126 lb/in
Break Strength: 90 lb/in
Yield Elongation: 12 %
Break Elongation: 100 % Tear Resistance (min. average) ASTM D1004 42 lbs 45,000 lbs Puncture Resistance (min. average) ASTM D4833 90 lbs 45,000 lbs Stress Crack Resistance (4) ASTM D5397 500 hr per GRI GM 10 Carbon Black Content (range) ASTM D4218 (4) 2.0 - 3.0 % 20,000 lbs Carbon Black Dispersion ASTM D5596 Note 5 - 45,000 lbs Oxidative Induction Time (OIT) (7) 200,000 lbs
Standard OIT (min average) ASTM D3895 100 min
High Pressure OIT (min average) ASTM D5885 400 min Oven Aging at 85oC (7), (8) ASTM D5721 per each formulation Standard OIT (min avg) - % retained after 90 ASTM D3895 55 % days
High Pressure OIT (min avg) - % retained after ASTM D5885 80 % 90 days UV Resistance (9) ASTM D7238 per each formulation (9) Standard OIT (min average) ASTM D3895 NR
High Pressure OIT (min avg) - % retained after ASTM D5885 50 % 1600 hrs (11)
2.19 02596-7 394.107.001 SECTION 02596
HIGH DENSITY POLYETHYLENE (HDPE) LINING MATERIAL
(1) Alternate the measurement side for double sided textured sheet.
(2) Machine direction (MD) and cross machine direction (XMD) average values should be on the basis of 5 test specimens each direction. Yield elongation is calculated using a gage length of 1.3 inches. Break Elongation is calculated using a gage length of 2.0 inches.
(3) The SP-NCTL per ASTM D5397 Appendix is not appropriate for testing geomembranes with textured or rough surfaces. Test should be conducted on smooth edges of textured rolls or on smooth sheets made from the same formulation as being used for the textured sheet materials. The yield stress used to calculate the applied load for SP-NCTL test should be the manufacturer's mean value via MQC testing.
(4) Other methods such as D1603 (tube furnace) or D6370 (TGA) are acceptable if an appropriate correlation to D4218 (muffle furnace) can be established.
(5) Carbon black dispersion (only near spherical agglomerates) for 10 different views: 9 in Categories 1 or 2 and 1 in Category 3.
(6) The manufacturer has the option to select either one of the OIT methods listed to evaluate the antioxidant content in the geomembrane.
(7) It is also recommended to evaluate samples at 30 and 60 days to compare the 90 day response.
(8) The condition of the test should be 20 hr. UV cycle at 75oC followed by 4 hr. condensation at 60oC.
(9) Not recommended since the high temperature of the Std-OIT test produces an unrealistic result for some of the antioxidants in the UV exposed samples.
(10) UV resistance is based on percent retained value regardless of the original HP-OIT value.
2.19 02596-8 394.107.001 SECTION 02596
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2.1.2.2 HDPE liner material shall meet the following inherent properties listed below:
INHERENT HDPE GEOMEMBRANE PROPERTIES(1) (60 mil NOMINAL VALUES) PROPERTY TEST METHOD VALUE UNITS
Secant Modulus ASTM D5323 60,000 lb/in Melt Index ASTM D1238 1.0 g/10 min (maximum)
(1) These properties are primarily inherent in the resin type used to produce polyethylene geomembranes and are not typically included as part of routine quality control testing. (2) 100oC and 100% Relative Humidity
2.1.3 Labeling Geomembrane Rolls:
2.1.3.1 Labels on each roll or factory panel will identify:
- The thickness of the material. - The length and width of the roll or factory panel. - The Manufacturer. - Directions to unroll the material. - Product identification. - Lot number. - Roll or field panel number.
PART 3 - EXECUTION
3.1 GEOMEMBRANE INSTALLATION:
3.1.1 Related Earthwork:
3.1.1.1 The Contractor shall ensure that all related earthwork requirements under this Section are complied with:
a. Geomembrane liners will be installed as an upper layer of each composite liner construction. The geomembrane installations will be performed on a firm, smooth,
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soil constructed according with the Specifications. The final surface will be free from stones, clumps, sticks or any other material that may puncture the membrane. Installation of the geomembrane on loose or gravelly soils is prohibited. Loose soils shall include soils where the upper surface is moist, but has a dry interface underneath. The soil moisture content shall be consistent throughout the material. The prepared surface shall be continuously maintained to prevent deterioration from the effects of wind, drying and excessive moisture in accordance with Section 02292, Paragraph 3.2.
b. No geomembrane will be placed onto an area which has become softened by precipitation or which has cracked due to desiccation. Appropriate methods of moisture control are the responsibility of the Contractor.
c. The Geomembrane Installer shall certify in writing that the final soil liner or GCL surface on which the membranes are to be installed are acceptable.
d. Free edges of HDPE liner shall be secured in such a manner as to prevent uplift by wind or the intrusion of water under the liner. Edge protection shall include sandbags, polyethylene sheeting or other methods as deemed necessary by the Contractor and approved by the Engineer. Any damage to underlying GCLs or soil liner shall be repaired at the Contractor’s expense.
e. The HDPE membrane will be temporarily anchored within an anchor trench constructed to the dimensions shown in the Contract Drawings. Care will be taken while backfilling the trenches to prevent damage to the geomembrane. Both the primary and secondary HDPE membranes will be anchored in the same trench.
3.1.2 Geomembrane Deployment:
3.1.2.1 HDPE liner system will be deployed according to the following procedures:
a. Placement of the geomembrane panels will be according to the approved location and position plan provided by the Installer. Placement will follow all instructions on the boxes or wrapping containing the geomembrane materials which describe the proper methods of unrolling panels. The field panel installation schedule is left to the preference of the Contractor, but the method chosen must minimize erosion of the underlying soil liner and the potential for wind damage.
b. The method of placement must ensure that:
2.19 02596-10 394.107.001 SECTION 02596
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- Deployed geomembrane must be visually inspected for uniformity, tears, punctures, blisters or other damage or imperfections. Any such imperfections shall be immediately repaired and reinspected.
- No equipment used will damage the geomembrane by handling, trafficking, leakage of hydrocarbons, or other means. Equipment, including ATVs, will not be allowed to travel directly on the geomembrane during the installation of overlying soils or geosynthetic layers unless otherwise determined by the Engineer.
- No personnel working on the geomembrane will smoke, wear damaging shoes, or engage in other activities which could damage the geomembrane.
- The prepared surface underlying the geomembrane must not be allowed to deteriorate after acceptance and must remain acceptable up to the time of geomembrane placement and until completion of the project.
- Adequate temporary loading and/or anchoring (e.g., sand bags, tires), not likely to damage the geomembrane, will be placed to prevent uplift by wind (in case of high winds, continuous loading is recommended along edges of panels to minimize risk of wind flow under the panels). - Direct contact with the geomembrane will be minimized; i.e., the geomembrane in excessively high traffic areas will be protected by geotextiles, extra geomembrane, or other suitable materials.
- The preferred method to install geomembrane is to unroll the material using low ground pressure, rubber tired or rubber tracked equipment. Dragging the geomembrane over prepared soil liner should be minimized.
c. Any damage to the geomembrane panels or portions of the panels as a result of placement must be replaced or repaired at no cost to the Owner. The decision to replace or repair any panel or portions of panels will be made by the Engineer.
d. The Engineer will assign an "identification number" to each geomembrane panel placed. This number will be consistent with the number used by the Installer. The number system used will be simple, logical and identify the relative location in the field.
e. When deploying a textured HDPE geomembrane over a GCL, a temporary slip sheet will be used to minimize friction and to allow the textured geomembrane to be more
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easily moved into its final position. To prevent premature hydration, only the amount of GCL that can be inspected, repaired, and covered in the same day shall be installed.
3.1.3 Seaming:
3.1.3.1 The seaming procedures below shall be implemented, where applicable, during installation of the geomembrane. The seaming procedures are as follows:
a. Generally, all seams whether field or factory will be orientated parallel to the line of slope, not across slope. This specification applies to all slopes in excess of 10 percent grade. All horizontal seams will be a minimum of 5 feet from the toe of the side slopes. At liner penetrations and corners the number of seams will be minimized.
b. The area of the geomembrane to be seamed shall be cleaned and prepared according to the procedures specified by the material manufacturer. Any abrading of the geomembrane will not extend more than one-half inch on either side of the weld. Care will be taken to eliminate or minimize the number of wrinkles and "fishmouths" resulting from seam orientation. c. Field seaming is prohibited when either the air or sheet temperature is below 32oF or when the sheet temperature exceeds 158oF or when the air temperature is above 120oF. At air or sheet temperatures between 32oF and 40oF seaming shall be conducted directly behind a preheating device. In addition, seaming shall not be conducted when geomembrane material is wet from precipitation, dew, fog, etc., or when winds are in excess of 20 miles per hour.
d. Seaming shall not be performed on frozen or excessively wet underlying soil surfaces.
e. Seams will have an overlap beyond the weld large enough to perform destructive peel tests, but not exceed 5 inches. Any material used to temporarily bond adjacent geomembrane panels must not damage or leave the geomembrane altered in any manner.
f. The Contractor shall perform trial seams on excess geomembrane material. A 1 foot by 3 foot seamed liner sample will be fabricated with the seam running down the 3 foot length in the center of the sample. Such trial seaming will be conducted prior to the start of each seaming session for each seaming crew, change in machine or every 4 hours, after any significant change in weather conditions or geomembrane
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temperature, or after any change in seaming equipment. From each trial seam, two field test specimens will be taken. The test specimens will be 1-inch by 12-inch strips cut perpendicular to the trial seam. These specimens will be peel tested using a field tensiometer, and recorded as pass (failure of liner material) or fail (failure of seam). Upon initial failure, a second trial seam will be made; if both test specimens do not pass, then the seaming device and its operator will not perform any seaming operations until the deficiencies are corrected and two successive passing trial seam test specimens are produced. Completed trial seam samples cannot be used as portions of a second sample and must be discarded.
g. Seams up side slopes will be continuous through the anchor trench. The primary and secondary geomembranes will be seamed along the bottom of the trench. No fishmouths shall be allowed within the seam area. Where fishmouths occur, the material shall be cut, overlapped and an overlap weld shall be applied. Where necessary, patching using the same liner material will be welded to the geomembrane sheet.
h. Where seams cannot be nondestructively tested in accordance with Section 3.1.4.1 of this Specification due to the geometry of the completed seams, a single layer of geomembrane shall be cap seamed over the subject seam and nondestructively tested if practical.
i. Acceptable seaming methods for HDPE geomembrane are:
- extrusion welding using extrudate with identical physical, chemical and environment properties - hot wedge welding using a proven fusion welder and master seamer.
j. Seaming device shall not have any sharp edges which might damage the geomembrane liner. Where self-propelled seaming devices are used, it will be necessary to prevent "bulldozing" of the device into the underlying soil.
3.1.4 Seam Testing:
3.1.4.1 The Contractor shall perform nondestructive seam testing on 100 percent of all field seams. The following test method and procedures may be used:
a. Vacuum testing will be used on all seams not tested using air pressure testing. Using an approved vacuum box, the following procedures will be followed:
2.19 02596-13 394.107.001 SECTION 02596
HIGH DENSITY POLYETHYLENE (HDPE) LINING MATERIAL
- apply a soapy water mixture over the seam - place vacuum box over soapy seam and form a tight seal - create a vacuum by reducing the vacuum box pressure to 5 psi (35 KPa) for a minimum of 5 seconds - observe through the vacuum box window any bubbles for a minimum of 5 seconds - where bubbles are observed, mark seam for repair - move vacuum box further down seam overlapping tested seam by 3 inches - where hot wedge seaming has been performed, the overlap must be cut back to the weld - all vacuum testing will be conducted under the direct observation of the Engineer.
b. Air pressure testing may be used in place of the vacuum box if double track hot wedge welding has been utilized to seam HDPE geomembrane. Using approved pressure testing equipment, the following procedures will be followed:
- seal one end of the air channel separating the double hot wedge welds - insert pressure needle into air channel at this end - seal open end of channel, and pressurize the air channel to 25 psi - monitor pressure gauge for 3 minutes and determine whether pressure is maintained without a loss of more than 2 psi. - if the pressure test fails, then localize the leak and mark the area for repair - air pressure testing will be conducted under the direct observation of the Engineer.
3.1.4.2 In addition to nondestructive seam testing, the Contractor will perform destructive testing. The destructive testing procedures are as follows:
a. Test samples will be prepared by the Installer every 1,000 feet of seam length, a minimum of one test for each seaming machine per day, or more frequently at the discretion of the Engineer. Sample location and size will be selected by the Engineer. The sample size (12 x 56 inches) will be large enough to produce three sets of test specimens for the following tests:
- Seam Shear Strength, ASTM D6392 - Peel Adhesion, ASTM D6392 - Adjacent Geomembrane Elongation, ASTM D6392
b. Ten specimens will compose a set. Half of these will be tested for peel and the other half for shear strength. Each specimen will be 1-inch wide and 12-inches long with
2.19 02596-14 394.107.001 SECTION 02596
HIGH DENSITY POLYETHYLENE (HDPE) LINING MATERIAL
the field seam at the center of the specimen. The 56-inch sample length will first be cut at the ends to produce two field peel test specimens. The remaining 54-inches will be divided into thirds and one-third submitted to the Contractor, one-third to the independent testing laboratory and one-third to the Engineer for storage and future reference.
c. Test specimens will be considered passing if the minimum values below are met or exceeded for all five test specimens tested by the independent laboratory. All acceptable seams will lie between two locations where samples have passed.
Field Seam Specification Limit Test Properties HDPE Method
Shear Strength at 120 ASTM Yield (lb/in width) D6392
Peel Adhesion (lb/in) 91 & Film Tear Bond ASTM (Wedge Weld Seam) D6392
78 & Film Tear Bond (Extrusion Weld Seam)
Adjacent Geomembrane 100% ASTM Elongation D6392
d. Unacceptable locus of break pattern: -Hot Wedge: AD and AD-Brk >25% -Extrusion Fillet: AD1, AD2, and AD-WLD (unless strength is achieved)
3.1.4.3 If a sample fails destructive testing, the Contractor shall ensure that: the seam is reconstructed in each direction between the location of the sample which failed and the location of the next acceptable sample; or the welding path is retraced to an intermediate location at least ten feet in each direction from the location of the sample which failed the test, and a second sample is taken for an additional field test. If this second test sample passes, the seam must be then reconstructed between the location of the second test and the original sampled location. If the second sample fails, the process must be repeated.
3.1.4.4 If double track hot-wedge welding is used, the Engineer and the Installer must agree on the track weld that will be used in the destructive testing. The weld chosen inside or outside must be consistently tested and pass according to the criteria above.
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HIGH DENSITY POLYETHYLENE (HDPE) LINING MATERIAL
3.1.4.5 All holes created by cutting out destructive samples will be patched by the Contractor immediately with an oval patch of the same material welded to the membrane using extrusion welding. The patch seams will be tested using a vacuum box and using the procedures described above. Work will not proceed with materials covering the geomembrane until passing results of destructive testing have been achieved.
3.1.5 Liner Repair:
3.1.5.1 All imperfections, flaws, construction damage, destructive and nondestructive seam failures will be repaired by the Installer. The appropriate methods of repair are listed below:
- patching, used to repair holes, tears, undispersed raw materials and contamination by foreign matter
- grinding and rewelding, used to repair small sections of extruded seams
- spot welding or seaming, used to repair pinholes or other minor, localized flaws
- capping, used to repair large lengths of failed seams
- topping, used to repair areas of inadequate seams, which have an exposed edge
- removing bad seam and replacing with a strip of new material welded into place (used with large lengths of fusion seams).
3.1.5.2 The actual method used will be agreed upon by the Engineer, Installer and Contractor. All repairs requiring abrading will be patched within one hour of the abrasion procedure. All defects that are patched will have the patch overlap the edge of the defect by a minimum of 6 inches. The patch will be cut with rounded edges (no corners). In the case of a large patch, the underlying geomembrane will be cut appropriately to avoid trapping gases and moisture between the two sheets.
3.1.5.3 During repair, the Engineer must be present and observe the procedures as well as all nondestructive testing of the repair seams. If the repair is very large, destructive testing may be required at the discretion of the Engineer. Any failure of repaired seams will require that the patch be removed, replaced and retested until passing results are achieved.
3.1.6 Construction Material Placement and Penetrations:
2.19 02596-16 394.107.001 SECTION 02596
HIGH DENSITY POLYETHYLENE (HDPE) LINING MATERIAL
3.1.6.1 All granular materials placed above geomembrane shall be spread with a minimum initial lift thickness of 12 inches using tracked equipment with ground pressures not exceeding 5 pounds per square inch. No construction equipment will be driven directly on the geomembrane. All rubber-tired vehicles will access construction above geomembranes from temporary access roads built a minimum of 3 feet above the liner. Extra geotextile or geomembrane layers shall be placed on or beneath all access roads or high trafficked areas. Any placement operation which results in damage to the underlying geomembrane, or in the opinion of the Engineer, has the potential of damaging the underlying geomembrane, shall immediately cease and be modified to prevent such damage.
3.1.6.2 Placement of overlying select fill shall be performed in a systematic manner in accordance with this Section and Section 02225. Multiple cover spreading points will not be allowed. One initial spreading location shall be established, and the work shall proceed from this location towards a free end of the geomembrane. Select fill must be placed using vertical placement techniques. No horizontal pushing of the initial select fill lift above the geomembrane will be allowed.
3.1.6.3 Wrinkles that develop from normal placement procedures must be controlled such that the underlying geomembrane does not fold over. Small wrinkles, defined as having their height less than or equal to one-half their base width, may be trapped and pushed down by the overlying soil. Any wrinkle which becomes too large and uncontrollable or which folds the geomembrane over must be brought to the attention of the Engineer. The Engineer will determine how to proceed, and his decision will be final. If necessary, the geomembrane will be uncovered, cut, laid flat, seamed by extrusion welding and non-destructively tested. Any wrinkle repairs within 10 feet of the cell valley shall be uncovered, cut, laid flat, seamed by extrusion weld, nondestructively tested and covered with a cap strip which is extrusion-welded and nondestructively tested.
3.1.6.4 Liner system penetrations will be constructed for the landfill liner development. The configuration of these penetrations is detailed in the Contract Drawings. A prefabricated HDPE boot, HDPE plate and/or penetration pipe assembly shall be installed around each liner system penetration as shown. The penetration assembly shall be attached to each respective geomembrane liner by the extrusion weld process. Seams and materials used at these locations will be carefully constructed and inspected to insure proper construction has been achieved. Nondestructive testing will be performed on all seams where such testing is possible, otherwise refer to Paragraph 3.1.3.1(h). Prefabricated HDPE sections shall be certified by the manufacturer for completeness of all welds. Shop drawings are required for all prefabricated HDPE items.
2.19 02596-17 394.107.001 SECTION 02596
HIGH DENSITY POLYETHYLENE (HDPE) LINING MATERIAL
3.17 Leak Location Survey: Secondary and primary geomembrane leak location surveys shall be conducted at the expense of the Contractor using an electronic method described in ASTM D7007 in accordance with Specification Section 02594, “Liner System Performance Testing”.
3.2 POST-CONSTRUCTION:
3.2.1 The Installer of the geomembrane materials will prepare and the Contractor shall submit, to the Engineer, record drawings illustrating the following information:
- dimensions of all geomembrane field panels - panel locations referenced to the Contract Drawing Plans - identify all field seams and panels with the appropriate number or code - location of all patches, repairs and destructive testing samples
3.2.2 Record drawing(s) will be submitted for each geomembrane layer constructed.
3.2.3 Warranty: The Contractor shall obtain and submit to the Engineer from the Manufacturer and Installer separate written warranties guaranteeing for a 20 year and 2 year period (respectively) from the date of issuance of the Certificate of Substantial Completion that the liner materials and workmanship specifically provided or performed under this Contract shall be free from defects. Said warranty shall apply to normal use and service by the Owner as described in Contract Specifications and as shown on the Contract Drawings. It shall specifically exclude mechanical abuse or puncture by machinery, equipment, or people, exposure of the liner to harmful chemicals or catastrophe due to earthquake, flood or tornado. Such written warranty shall provide for the repair or replacement of the defect or defective area of lining materials upon written notification and demonstration by the Owner of the specific nonconformance of the lining material or installation with the project Specifications. Such defects or nonconformance shall be repaired or replaced within a reasonable period of time of such notification. The Owner agrees to pay an amount equal to the then current sales and installation price of the defective portion of the lining material multiplied by a fraction, the numerator of which shall be the number of years elapsed since the commencement of the warranty period and the denominator of which shall be the warranty period, provided that portion of the area in question has been made available to the Manufacturer/Installer and that such areas have been cleared of all liquids, sludges, earth, sand or gravel.
2.19 02596-18 394.107.001 SECTION 02596
HIGH DENSITY POLYETHYLENE (HDPE) LINING MATERIAL
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - HIGH DENSITY POLYETHYLENE (HDPE) LINING MATERIAL:
4.1.1 Measurement for payment for High Density Polyethylene (HDPE) Lining Material shall be based on the number of square feet of material placed as measured to the nearest foot, excluding any overlaps and material in the anchor trench.
4.2 PAYMENT - HIGH DENSITY POLYETHYLENE (HDPE) LINING MATERIAL:
4.2.1 For High Density Polyethylene (HDPE) Lining Material, not included in other unit or lump sum price items, payment for High Density Polyethylene (HDPE) Lining Material will be made at the applicable price stated in the Bid.
4.2.2 The Owner will pay for HDPE Lining Material delivered and properly stored on-site upon receipt and acceptance of all required submittals, shop drawings and conformance test results. Payment for installation of the material will not be made until all acceptable destructive and non-destructive test results have been received. The Owner shall retain 10 percent of the price of the HDPE Lining Material until the Contractor provides acceptable quality control documentation, record drawings and warranties.
END OF SECTION
2.19 02596-19 394.107.001 SECTION 02599
INTERFACE FRICTION TESTING
PART 1 – GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for the interface friction testing as specified and/or directed.
1.1.2 Direct shear box testing will be conducted to obtain the peak and residual strength parameters (adhesion and interface friction angle) at the following interfaces:
Liner System • Site specific geosynthetic clay liner (GCL) and site specific textured 60 mil HDPE geomembrane; and • Site specific textured 60 mil HDPE geomembrane and site specific secondary soil liner.
1.1.3 Testing shall be performed according to ASTM D5321 or ASTM D6243 by an Accredited Geosynthetics Laboratory at the Contractor’s expense.
1.2 PRE-QUALIFICATIONS:
1.2.1 The Contractor shall submit six copies of Accredited Geosynthetic Laboratory qualifications package including accreditation designation number to the Engineer for approval.
1.2.2 This testing is being performed as part of the required conformance testing for Section 02596 – High Density Polyethylene (HDPE) Lining Material and Section 02236 – Geosynthetic Clay Lining Material (GCL). Initial material submittals for all products to be used in the testing shall be submitted to the Engineer for review. Final material acceptance will be based on conformance test results.
PART 2 – PRODUCTS
2.1 GEOSYNTHETIC MATERIALS: The Contractor is responsible for supplying site specific geosynthetic materials including HDPE geomembrane and GCL to the testing laboratory, in sufficient quantities to complete all testing. Samples to be used in testing shall be taken from materials delivered to the site as part of conformance testing.
6.19 02599-1 394.107.001 SECTION 02599
INTERFACE FRICTION TESTING
2.2 SOIL MATERIAL: The Contractor shall supply site specific soil material in sufficient quantities to complete all testing.
PART 3 - EXECUTION
3.1 TEST CONDITIONS
3.1.1 The interfaces shall be tested under “as constructed” conditions and care will be taken to ensure consistent soil moisture and test preparation times.
3.1.2 General Test Conditions for Liner System: Testing of each interface shall be performed according to ASTM D5321 under the following general test conditions:
a. Testing is to be conducted using a minimum 12-inch by 12-inch upper shear box and a 12-inch by 16-inch lower shear box; b. Test 1 – HDPE geomembrane to GCL shall be tested under saturated conditions with the GCL hydrated under the specified normal load. Test 2 – HDPE geomembrane to secondary soil liner, shall be tested under unsaturated conditions to model field installation; c. Normal loads shall be applied for a minimum of 24 hours prior to shear; d. Normal loads will model expected overburden stress conditions. The interface testing shall be performed at the following normal loads: 5000 psf, 10,000 psf and 15,000 psf; e. The strain rate for shearing both interfaces shall be 0.1 mm per minute (0.004 inch per minute); and f. The geosynthetic materials shall be tested in both the material direction and transverse direction to simulate actual field installation conditions.
3.1.2.1 Test Specimen Orientation:
a. Test 1 – HDPE Geomembrane to GCL Upper Shear Box: • A substrate of 2-inches of firmly compacted sand. • Site Specific 60 mil textured HDPE geomembrane (fastened to the box).
Lower Shear Box: • Site specific GCL (Fastened to the Box). • A substrate of 2-inches of firmly compacted sand.
6.19 02599-2 394.107.001 SECTION 02599
INTERFACE FRICTION TESTING
b. Test 2 – HDPE Geomembrane to Secondary Soil Liner Upper Shear Box: • A substrate of 2-inches of firmly compacted sand. • Site specific 60 mil textured HPDE geomembrane (fastened to the box).
Lower Shear Box: • A minimum of 2-inches of site specific secondary soil liner compacted to a minimum of 90% of the Modified Proctor Density at or above the optimum moisture content.
3.2 REPORTING & ACCEPTANCE CRITERIA
3.2.1 Test Result Reporting: After completion of interface testing, the testing laboratory shall provide a minimum of three (3) copies of a summary report outlining the test preparations, conditions, procedures and results including applicable graphs, photographs, and figures. The test summary report shall be provided to the Engineer for review 2 weeks prior to installation of the secondary geomembrane and capping system geomembrane. If review of the initial testing results indicates the geosynthetic materials do not meet the acceptance criteria, additional interface testing may be required by the Engineer at the Contractor’s expense.
3.2.2 Acceptance Criteria: The Contractor shall supply geosynthetic materials for the project which will result in a post-construction total peak shear strength for all interfaces and both directions described in this Section as outlined below:
• 3,215 psf at 12,000 psf normal load
Final acceptance of the material will be based upon the Engineer’s review of the test reports described in this Section.
All geosynthetic interface results shall represent post-construction strengths. Additional interface testing from in-place materials shall be performed by the Contractor, as requested by the Engineer, if there is evidence that geosynthetics were damaged during deployment or material properties have changed. This additional testing shall be performed at the Contractor’s expense.
6.19 02599-3 394.107.001 SECTION 02599
INTERFACE FRICTION TESTING
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - INTERFACE FRICTION TESTING:
4.1.1 Measurement for Interface Friction Testing shall include the costs of all labor, materials, equipment, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - INTERFACE FRICTION TESTING:
4.2.1 For Interface Friction Testing, not in other unit or lump sum price items, payment for Interface Friction Testing will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 02599-4 394.107.001 SECTION 02641
SMOOTH INTERIOR CORRUGATED POLYETHYLENE PIPE AND END SECTIONS
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Smooth Interior Corrugated Polyethylene Pipe and End Sections as shown on the Plans, as specified and/or directed.
PART 2 - PRODUCTS
2.1 MATERIALS:
2.1.1 Smooth interior corrugated polyethylene pipe shall conform to the requirements of Section 706-12 of the New York State Standard Specifications latest edition. The units shall conform to the shape, dimensions and thickness shown on the Contract Drawings or as listed in the Additional Instructions.
2.1.2 Polyethylene end sections shall conform to the requirements of Section 706-12 of the New York State Standard Specifications, latest edition.
2.1.3 All smooth interior corrugated polyethylene pipe and end sections shall be of the same manufacturer and shall be designed to be joined by couplings or other positive mechanical means approved by the Engineer.
2.2 SUBMITTALS:
2.2.1 The Contractor shall submit six (6) copies of the manufacturer’s material specifications for each item to be supplied under this Section.
PART 3 - EXECUTION
3.1 CONSTRUCTION:
3.1.1 Smooth interior corrugated polyethylene pipe shall be installed in the locations shown on the Contract Drawings. Connections and embedment shall be performed in strict accordance with all manufacturer's recommendations and as indicated on the drawings.
6.19 02641-1 394.107.001 SECTION 02641
SMOOTH INTERIOR CORRUGATED POLYETHYLENE PIPE AND END SECTIONS
3.1.2 All pipe shall be laid in reasonably close conformity to line and grade and shall have a full firm and even bearing at each joint and along the entire length of pipe. Pipe laying shall begin at the downstream end and progress upstream. Any single run of pipe, including end sections, shall consist wholly of the same material unless otherwise directed by the Engineer.
3.1.3 All pipe shall be handled and assembled in accordance with the manufacturer's instructions except as modified on the Plans or by the Engineer's written order.
3.1.4 Special care shall be exercised in placing and compacting material immediately adjacent to pipes in order to avoid damage to the pipe and to prevent pipe misalignment.
3.1.5 Movement of construction equipment, vehicles and loads over and adjacent to any pipe shall be done at the Contractor's risk.
3.1.6 Corrugated polyethylene pipe connections for making field joints shall consist of corrugated bands, so constructed as to lap on equal portions of each culvert section to be connected. All connections shall be an approved type, fabricated and installed so that a secure and firm pipe connection may be readily made in the field.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - SMOOTH INTERIOR CORRUGATED POLYETHYLENE PIPE:
4.1.1 Measurement for which payment will be made for Smooth Interior Corrugated Polyethylene Pipe shall be the number of linear feet of straight pipe incorporated in the work, in accordance with the Plans and orders, measured along the center line of the finished sewer less the space occupied by drainage structures. For all structures, measurement will be to the outside face of the structure.
4.2 PAYMENT - SMOOTH INTERIOR CORRUGATED POLYETHYLENE PIPE:
4.2.1 For Smooth Interior Corrugated Polyethylene Pipe, not included in other unit or lump sum price items, payment for Smooth Interior Corrugated Polyethylene Pipe will be made at the applicable price stated in the Bid.
6.19 02641-2 394.107.001 SECTION 02641
SMOOTH INTERIOR CORRUGATED POLYETHYLENE PIPE AND END SECTIONS
4.2.2 The price bid shall include the cost of excavation, lining, special backfill, maintenance of traffic, topsoil and seeding, asphaltic concrete paving and saw cutting asphalt pavement or concrete pavement as required, and all materials, equipment and labor necessary to complete the work as shown and specified.
4.3 MEASUREMENT - END SECTIONS:
4.3.1 Measurement for which payment will be made for End Sections shall be the number of end sections incorporated in the work, in accordance with the Contract Drawings.
4.4 PAYMENT - END SECTIONS:
4.4.1 For End Sections, not included in other unit or lump sum price items, payment for End Sections will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 02641-3 394.107.001 SECTION 02674
HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for High Density Polyethylene (HDPE) Pipe and Fittings as shown on the Plans, as specified, and/or directed.
PART 2 - PRODUCTS
2.1 MATERIAL:
2.1.1 All pipes shall be of high density high molecular weight material using PE 4710 grade resin and having a cell classification number of 445574C. All HDPE pipe shall conform to ASTM D3350.
2.1.2 All perforated HDPE pipe shall have a SDR of 11 or lower unless otherwise specified. Dual contained solid pipe shall have a SDR of 17 or lower unless otherwise specified.
2.1.3 Standard length of pipe shall be a minimum of 40 feet.
2.1.4 All perforated pipe shall have 5/8-inch diameter perforations on 5-inch centers, in four rows 90 degrees apart. Smooth perforations, no burrs, or shavings.
2.2 CENTRALIZERS: Dual contained piping shall be factory fabricated for simultaneous fusion with internal centralizers spaced no greater than 4-feet on center and fused in place. Centralizers shall be furnished so the annular space between the HDPE pipes is evenly distributed within the conveyance line. The centralizers shall be configured to allow for liquid to flow freely along the invert of the pipe.
2.3 END SEALS: End seals shall be factory pre-fabricated fixed end seals which anchor the carrier and containment pipes together. End seals shall accommodate simultaneous fusion and centralizers shall be fused in place.
6.19 02674-1 394.107.001 SECTION 02674
HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS
2.4 Cleaning Cables: The Contractor shall provide 3/16” high-strength coated stainless steel cleaning cables within all HDPE piping within the cells (Primary and Secondary lines). The cable shall extend continuously between the cleanouts at the western and eastern end of each cell. No splices shall be allowed within the cell. Contractor shall allow sufficient slack on each end for connection to cleaning equipment. Cable shall be S.S. IWRC, 7x19 in conformance with MIL-W-1511A.
2.5 COUPLINGS AND FUSION:
2.5.1 Joining of HDPE pipe shall be by butt fusion or where circumstances warrant couplings shall be by the electro-fusion socket type connection that provides a welded connection. All joints shall be internally de-beaded after the joining of the pipe for a smooth interior finish. Electro-fusion locations will require Engineer approval.
2.5.2 The socket type couplings shall be manufactured by GF ELGEF, or equal.
2.6 FLANGES: Provide ANSI B16.1, Class 150 flanges for all flange connections. Backup rings shall be lightweight stainless steel.
2.6.1 Bolting of Flanges: Material used for bolts and studs shall be stainless steel conforming to ASTM A276, Type 304, and material for nuts shall be stainless steel conforming to ASTM A276, Type 304. Dimensions of bolts, studs, and nuts shall conform to ANSI B18.2.1 and ANSI B18.2.2 with threads conforming to ANSI B1.1 coarse type with Class 2A fit for bolts and studs, and Class 2B fit for nuts. Bolts or studs shall extend through the nuts and may have reduced shanks of a diameter not less than the diameter at root of threads. Stainless steel bolts shall have American Standard regular square or heavy hexagon heads and shall have American Standard heavy, semi-finished hexagonal nuts.
2.7 SUBMITTALS:
2.7.1 The Contractor shall submit to the Engineer for approval, data for all pipe and fittings which he proposes to use. The data shall demonstrate complete compliance with the provisions of the plans and specifications.
2.7.2 The Contractor shall submit to the Engineer for approval, manufacturer’s certifications for all personnel that will fusion weld the pipe and fittings along with dates and duration of employment.
6.19 02674-2 394.107.001 SECTION 02674
HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS
2.7.3 The Contractor shall submit the cleaning cable information and all associated hardware.
PART 3 - EXECUTION
3.1 QUALITY ASSURANCE:
3.1.1 All pipe will be inspected on delivery, and materials that do not comply with the Specification will be rejected. The Contractor shall furnish all labor required to handle the pipe during inspection and shall remove the rejected materials from the site of the work.
3.2 INSTALLATION:
3.2.1 Installation of all pipe, fittings, specials, adapters and appurtenances shall conform to the Manufacturer's recommendations and the following summary of installation recommendations. Where specifications and recommendations conflict, the strictest shall apply.
3.2.2 Electrofusion couplings shall not be used in the cell without prior Engineer’s approval.
3.2.3 Proper implements, tools and facilities satisfactory to the Engineer shall be provided and used by the Contractor for the safe and convenient execution of the work.
3.2.4 Cutting of pipe shall be done with pipe cutters, motor drive saws using abrasive disks, or with handsaws as required. Where machining is necessary for cut ends or for extending factory machining, it shall be done in accordance with the manufacturer’s recommendations for the type of pipe and joint used. The flame cutting of pipe by means of an oxyacetylene torch will not be allowed.
3.2.5 Pipe shall be laid to the lines and grades on a prepared earth subgrade or special embedment as shown, specified or directed.
3.2.6 The interior surface of all pipe shall be clean when installed, and shall be kept clean until final acceptance. Removable end caps shall be placed on all open ends of pipelines when pipe laying is not actively in progress. The bulkheads shall be designed to prevent the entrance of dirt, debris or small animals, and shall not be removed until pipe laying is resumed.
6.19 02674-3 394.107.001 SECTION 02674
HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS
3.3 LEAKAGE TEST:
3.3.1 All solid HDPE Pipes and Fittings shall be tested after joining for leakage by the Contractor at no cost to the Owner in accordance with the manufacturer's recommendation for the intended use. No leakage is permitted, although appropriate allowances for expansion of pipe shall be taken into consideration for the test pressure. Refer to Section 15075, “Piping Systems”.
3.4 INTERNAL PIPE INSPECTION:
3.4.1 The Contractor shall internally inspect all piping within Cell No. 6 and Cell No. 2 using color camera inspection following complete installation. The Contractor shall be responsible for all repairs and cleaning evident from construction. Three (3) final copies of video and logs shall be submitted for review and approval.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS:
4.1.1 Measurement for payment shall be the actual linear feet of pipe joined.
4.2 PAYMENT - HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS:
4.2.1 For High Density Polyethylene Pipe (HDPE) Pipe and Fittings, not included in other unit or lump sum price items, payment for High Density Polyethylene (HDPE) Pipe and Fittings will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 02674-4 394.107.001 SECTION 03210
REINFORCING STEEL
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for installing all Reinforcing Steel, welded wire fabric and accessories for cast-in-place concrete as shown on the Plans, as specified, and/or directed.
1.2 REFERENCES:
1.2.1 Reference to standard specifications for the following organizations is intended to specify minimum standards for quality of materials and performance of workmanship, and for standard test methods.
a. American Society for Testing and Materials (ASTM ) Publications, Latest Edition.
b. American Concrete Institute (ACI) Standards, Latest Edition.
c. American Welding Society (AWS) Publications, Latest Edition.
d. American National Standards Institute (ANSI) Publications, Latest Edition.
e. Concrete Reinforcing Steel Institute (CRSI) Publications, Latest Edition.
1.3 SUBMITTALS:
1.3.1 Shop Drawings: Indicate bar sizes, spacings, locations and quantities of reinforcing steel and wire fabric, bending and cutting schedules, and supporting and spacing devices. No work on fabricating or placing steel shall be done until such drawings and schedules have been approved.
1.3.2 Manufacturer’s Certificate: Submit certified copies of mill test report of reinforcement materials analysis.
1.3.3 Welder’s Certificate: Submit certification from welders employed on the work, verifying AWS qualification within the previous twelve months.
5.07 03210-1 SECTION 03210
REINFORCING STEEL
PART 2 - PRODUCTS
2.1 MATERIALS:
2.1.1 Reinforcing steel bars shall be free from defects, kinks, bends, rust, scale or other irregularities. Reinforcing mesh shall be of the electrically welded type, with wires arranged in rectangular or square patterns.
2.1.2 Reinforcing bars shall be deformed billet steel meeting the requirements of ASTM A615 Grade 60.
2.1.3 Steel wire fabric shall meet the requirements of ASTM A185.
2.1.4 Stirrup steel shall be cold drawn steel wire meeting the requirements of ASTM A82.
2.1.5 Epoxy coated reinforcing bars shall be deformed billet steel meeting the requirements of ASTM A775, Grade 60.
2.1.6 Galvanized reinforcing bars shall be deformed billet steel meeting the requirements of ASTM A767, Grade 60.
2.1.7 Accessory materials shall include: tie wire, minimum 16 gage annealed type. Epoxy- coated reinforcing bars shall be tied with plastic-; epoxy-; or nylon-coated tie wire. Chairs, bolsters, bar supports, and spacers shall be sized and shaped for strength and support of reinforcement during concrete placement conditions.
2.2 IDENTIFICATION AND PROTECTION OF BARS AND FABRIC:
2.2.1 Reinforcing steel shall be delivered to the work in strongly tied bundles identified with metal tags corresponding to the bar schedules and diagrams. Identification marks shall show quantity, producing mill, bar size, type of steel and grade mark.
2.2.2 All bars and fabric shall be stored off the ground and shall, at all times, be protected from moisture and be kept free from dirt, oil, or injurious coatings. Epoxy-coated reinforcing bars shall be stored on protective cribbing. If concreting is delayed for any considerable number of days after the reinforcing is placed in position, it shall be protected by covering with canvas or other satisfactory covering, or, if directed, shall be painted with a coat of neat cement grout.
5.07 03210-2 SECTION 03210
REINFORCING STEEL
2.2.3 Any bar or fabric having a scaly rust shall be cleaned. Epoxy-coated reinforcing bars that are cut, welded or otherwise damaged shall be repaired with patching material conforming to ASTM A775 and done in accordance with the Material Manufacturer's recommendation. Galvanized reinforcing bars that are cut, welded or otherwise damaged shall be repaired with patching material conforming to ASTM A767 and done in accordance with the Material Manufacturer's recommendation. The Contractor will be required to replace bars exhibiting severely damaged coatings.
PART 3 - EXECUTION
3.1 FABRICATION AND INSTALLATION:
3.1.1 Metal reinforcing shall be properly fabricated in accordance to references specified.
3.1.2 Metal reinforcing shall be properly placed in accordance to CRSI, ACI 301, ACI 318, ACI SP-66, as shown on the approved Shop Drawings and as herein directed.
3.1.3 Bars shall be bent in the shop to the shapes shown or required. Field bending shall be done only with the written approval of the Engineer. Field welding shall not be allowed without direct approval and supervision of the Engineer.
3.1.4 Unless otherwise shown, splices in tension reinforcement shall not be permitted, and splices in compression reinforcement shall be lapped 40 diameters. All bar splices shall be staggered, wherever possible. Locate splices not indicated on drawings, at point of minimum stress. Splice locations must be approved by the Engineer.
3.1.5 Reinforcing shall be securely tied and supported and must not be displaced during concrete placing operations. Epoxy-coated reinforcing bars shall rest on coated wire bar supports, or other acceptable materials. Dowels must be wired in place before concreting begins. All metal shall be kept away from exposed surfaces of concrete.
3.1.6 Conduit in slabs on grade shall be placed in a depression below the slab and the mesh run continuous over conduit. Conduit in slabs on forms shall be above the bottom reinforcing and below the top reinforcing. No conduit is permitted in thin joist slabs.
3.1.7 Cutting of bars to clear openings in walls or slabs is strictly prohibited. Warp bars around such openings.
5.07 03210-3 SECTION 03210
REINFORCING STEEL
3.1.8 Provide two #6 diagonal bars at each corner of every rectangular opening in walls, unless otherwise shown on the Plans.
3.1.9 All slabs, unless otherwise shown on the Plans, to be reinforced with not less than WWF 6 x 6 - W2.9 x W2.9 welded wire mesh.
3.1.10 Placing of concrete shall not be scheduled until all of the reinforcing for the section is secured in place and the reinforcing and forms have been approved by the Engineer or his representative. Contractor shall notify the Engineer 24 hours prior to a concrete pour.
3.1.11 Welded wire mesh in slabs is to be placed in the upper third of the depth of the slab. Lap 6" minimum. Fabric shall be straightened as required before placement.
3.1.12 Provide bent bars 6'-0" long of same size and spacing as horizontal bars for all corners of foundation walls, unless otherwise shown on the Plans.
3.1.13 Do not displace or damage vapor barrier.
3.1.14 For footing reinforcement - support bars on small precast concrete blocks; space at intervals as shown on the Plans and within minimum height specified above underside of slab or footing.
3.1.15 Reinforcement shall not be bent after being partially embedded in hardened concrete.
3.2 CONCRETE PROTECTION FOR REINFORCEMENT:
3.2.1 Unless otherwise shown or directed, concrete protection, measured from the surface of the bar, shall be the following:
3.2.1.1 For concrete deposited against the ground, without the use of forms...... 3 inches
3.2.1.2 For formed concrete in contact with the ground...... 2 inches
3.2.1.3 For slabs and walls contacting water or sewage...... 2 inches
3.2.1.4 For beams, girders and columns not directly exposed to ground and weather ...... 1-1/2 inches
3.2.1.5 For formed concrete exposed to the weather ...... 2 inches
5.07 03210-4 SECTION 03210
REINFORCING STEEL
3.2.1.6 For slabs and walls, not directly exposed to ground, weather, water or sewage...... 1 inch
3.2.2 Exposed reinforcing bars intended for bonding with future extensions shall be protected from corrosion by a covering of concrete or other approved material.
3.3 FIELD QUALITY CONTROL:
3.3.1 Field inspection will be performed under the provisions of Section 03300 or 03302.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - REINFORCING STEEL:
4.1.1 The quantity of Reinforcing Steel shall be determined by weight. Extra metal in laps will be included where authorized, where a single bar would be unreasonably long. The weight of devices for securing the reinforcement in position shall not be included in the quantity for payment. The quantity for which payment will be made will be the actual number of pounds of Reinforcing Steel placed as shown on the Plans and/or ordered by the Engineer.
4.2 PAYMENT - REINFORCING STEEL:
4.2.1 For Reinforcing Steel, not included in other unit or lump sum price items, payment for Reinforcing Steel will be made at the applicable price stated in the Bid.
END OF SECTION
5.07 03210-5 SECTION 03300
CAST-IN-PLACE CONCRETE
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for plain and reinforced Cast-In-Place Concrete work including accessory items of work herein described, as shown on the Plans, as specified, and/or directed.
1.2 REFERENCES:
1.2.1 Reference to standard specifications for the following organizations is intended to specify minimum standards for quality of materials and performance of workmanship, and for standard test methods.
a. American Society for Testing and Materials (ASTM) Publications, Latest Edition.
b. American Concrete Institute (ACI) Standards, Latest Edition.
c. Standard Specifications - Construction and Materials, New York State Department of Transportation (NYSDOT), Latest Edition, including Addenda thereto.
1.3 QUALITY ASSURANCE:
1.3.1 Perform work in accordance with ACI 301 and ACI 302.
1.3.2 Acquire cement and aggregate from same source for all work.
1.3.3 Conform to ACI 305R when concreting during hot weather, except as herein modified.
1.3.4 Conform to ACI 306R when concreting during cold weather, except as herein modified.
1.4 SUBMITTALS, SAMPLES AND TESTS:
1.4.1 Product Data: Provide data on joint devices, attachment accessories and admixtures.
3.08 03300-1 SECTION 03300
CAST-IN-PLACE CONCRETE
1.4.2 Concrete:
1.4.2.1 Samples and tests of all materials to be incorporated in the concrete shall be submitted in ample time for testing before delivery. All materials are subject to inspection and testing by a commercial testing laboratory approved by the Engineer at the Contractor’s expense. All materials are subject to approval by the Engineer prior to their delivery to the site.
1.4.2.2 The Contractor shall obtain from the manufacturer, prior to the actual delivery of the concrete, a statement giving the sources, specific gravities, and sieve analyses of the aggregates and the dry weights of cement and saturated-surface-dry weights of fine and coarse aggregate and quantities, type and name of admixture (if any) and of water per cubic yard of concrete that will be used in the manufacture of each class of concrete to be provided. This data shall be sent to the Engineer for review and approval.
a. Aggregates shall be tested for gradation, purity and accelerated soundness. Tests shall comply with ASTM C33, C136, ASTM C40, and ASTM C88. The source of the material shall not be changed without retesting.
b. Cement shall have representative mill test reports on physical and chemical requirements. All cement stored at job site or at concrete supplier’s place for over 60 days shall be tested for compliance with ASTM C150.
1.4.2.3 Contractor shall submit concrete mix design to be reviewed by the Engineer.
1.4.2.4 Tests of other materials may be required by the Engineer.
PART 2 - PRODUCTS
2.1 MATERIALS:
2.1.1 All materials shown, specified or required to be incorporated in cast-in-place concrete shall be of finest quality, and shall be delivered, stored and handled so as to prevent damage. Damaged or inferior materials will be rejected. Approved brands or sources must be used, without change for the entire project. All materials shall be proportioned to produce a well graded mixture of high density and maximum workability.
3.08 03300-2 SECTION 03300
CAST-IN-PLACE CONCRETE
2.1.2 Portland Cement shall be a standard brand in compliance with ASTM C150 Type I. Only one brand shall be used for exposed work. Generally, Type I cement shall be used; however, Types II or III may be employed with the approval of the Engineer or if shown, or specified.
2.1.3 Fine Aggregates shall be clean, sharp, natural sand, free from loam, clay, organic impurities or frozen materials and shall conform to ASTM C33 in all respects. Sand shall be tested for impurities in accordance with ASTM C40.
2.1.4 Coarse Aggregates shall consist of strong, clean, crushed limestone or crushed gravel, free from harmful material and meeting all of the requirements of ASTM C33. Coarse aggregate shall also comply with New York State Department of Transportation Material Designation 703- 02. Crushed limestone and crushed gravel shall meet the Physical Requirements (Testing) Designation 703-0201 and 703-0202, respectively.
2.1.5 Water used in mixing concrete shall be clean and free from all acid, alkali or organic matter and shall be obtained from a public water supply unless specifically permitted otherwise by the Engineer.
2.1.6 Ready Mix Concrete shall comply with ASTM Specification C94, this Specification, and used subject to the Engineer’s approval.
2.1.7 Admixtures, where shown or specified, shall be as follows:
a. Air entraining agent shall be “Daravair” or “Darex AEA” as manufactured by W.R. Grace Co., or Master Builder’s "MBVR", or equal meeting the requirements of ASTM C260.
b. Water reducing agent shall be Sika “Plastiment”, Master Builder’s “Pozzolith”, W.R. Grace’s "WRDA", or equal meeting the requirements of ASTM C494.
c. High range water reducers or superplasticizers shall be Sika “Sikament-FF”, W.R. Grace’s “Daracem-100” or “WRDA-19”, or equal meeting the requirements of ASTM C494.
2.1.8 Bonding Agent, where shown or specified, shall be “Dural 104” bonding compound manufactured by Dural International Corporation, “Sikadur 32 Hi Mod” by Sika Corporation, or equal.
3.08 03300-3 SECTION 03300
CAST-IN-PLACE CONCRETE
2.1.9 Anchorage Items, where shown or specified, shall be as follows:
a. Inserts for fastening shelf angles shall be malleable iron adjustable wedge type, with bolt and washer, if required, as manufactured by Hohman & Barnard, Inc., Richmond Screw Anchor Co., Inc., or equal.
b. Threaded inserts for fastening of soffits of concrete beams shall malleable iron, as manufactured by Hohman & Barnard, Inc., Richmond Screw Anchor Co., Inc., or equal.
c. Ceiling hanger inserts shall be standard type wire as manufactured by Hohman & Barnard, Inc., Heckman Building Products, Inc., or equal.
d. Masonry anchor slots shall be galvanized sheet metal, felt filled, as manufactured by Hohman & Barnard, Inc., Heckman Building Products, Inc., or equal.
e. Flashing reglets shall be O’Keefe’s Inc., PVC “Watertite Type P”, or equal to size and shape shown.
2.1.10 Flexible Sleeve, where shown or specified, shall be of resilient rubber with a flanged, serrated waterstop and shall be cast directly into the walls of the concrete structure as shown on the Contract Documents. Flexible sleeve shall conform to the following physical requirements:
ASTM TEST REQUIREMENTS PROPERTY METHOD MIN. MAX.
Tensile Strength, psi D412 1500 -
Ultimate Elongation, percent D412 450 -
Hardness, Type A durometer D2240 45 55
2.1.10.1 Flexible sleeve must permit a minimum of 10 degrees deflection in all directions. Flexible sleeve shall be “Lockjoint Flexible Manhole Sleeve” as manufactured by Chardon Rubber Company, or equal.
3.08 03300-4 SECTION 03300
CAST-IN-PLACE CONCRETE
2.1.11 Forms shall be wood, metal, or other approved materials as follows:
a. Plywood shall be Commercial Standard Douglas Fir, moisture resistant, concrete form plywood, at least 5-ply 5/8” thick.
b. Metal forms shall be as approved, and must produce surfaces equal to those specified for wood forms.
c. Form oil shall be an approved non-staining mineral oil, such as “Duogaurd II” by W.R. Meadows, or equal.
d. Form ties shall be of approved design, adjustable length and free of devices that will leave hole or depression larger than 7/8” diameter. When forms are removed no metal shall be left within 1” of finished surface.
2.1.12 Waterstops, where shown or specified, shall be minimum 3/8-inch thick across their entire section, heavy duty, serrated type manufactured from virgin polyvinyl chloride compound, “Model RB6-38H” as manufactured by Vinylex Corporation, or equal. They shall have a tensile strength of minimum 1800 psi and an elongation of minimum 200%.
2.1.12.1 Waterstops shall be open bulb type, 6-inch wide unless otherwise shown or directed by the Engineer. The waterstops shall be supported during concrete placement to prevent dislodgement and to insure that the ends remain at right angles to the joint. Field joints shall be butt welded with an electric iron in accordance with the manufacturer’s instructions.
2.1.12.2 Sample of the waterstops to be used shall be submitted to the Engineer for approval.
2.1.13 Premolded Joint Filler, where shown or specified, shall be premolded, resilient, non- extruding type, 1/2-inch thick unless shown otherwise, full depth of concrete section as manufactured by Celotex Corporation, “Fibre Expansion Joint Filler” by W.R. Meadows, or equal.
2.1.13.1 Sample of the premolded filler proposed to be used shall be submitted to the Engineer for approval.
2.1.14 Joint Sealant, where shown or specified, shall be elastomeric polyurethane sealant material, black in unexposed locations, and grey in exposed locations, and have balanced properties of elongation recovery and tensile strength, and shall be Sonneborn “Sonolastic NP1”, Sika “Sikaflex 1A”, or equal.
3.08 03300-5 SECTION 03300
CAST-IN-PLACE CONCRETE
2.1.15 Protective Covering for concrete finish slabs, where shown or specified, shall be “Orange Label Sisalkraft”, Polyethylene Film as manufactured by Fortifiber Corp., or equal.
2.1.16 Non-Shrink Grout, where shown or specified, shall be premixed compound consisting of non-metallic aggregate, natural aggregate, cement, water reducing and plasticizing agents; capable of developing minimum compressive strength of 2,400 psi in 48 hours and 7,000 psi in 28 days; such as “Masterflow” as manufactured by Master Builders, “SikaGrout 212” as manufactured by Sika, or approved equal.
2.1.16.1 Non-Shrink grout shall be used under structural steel column baseplates and all equipment baseplates. All work shall be done in strict accordance with the manufacturer’’s recommendations. At the request of the Engineer, the manufacturer’s representative shall be called to the job site for consultation regarding detailed use of the grout.
2.1.17 Grout for fillets, channels, or other non-structural applications shall consist of one (1) part cement (Portland Cement Type 2) and three (3) parts fine aggregate (sand) with sufficient mixing water for the intended application.
2.1.18 Cementitious Coating Materials, where shown or specified, shall be “Thoroseal” with “Acryle 60” bonding agent, as manufactured by Thoro System Products, “Anchor Masonry Surfacer” as manufactured by Anti Hydro Waterproofing Company, or equal.
2.1.19 Curing Compound shall be acrylic based “Kure-N-Seal” as manufactured by Sonneborn, acrylic based “CS-309”, or water based “VOCOMP-20” as manufactured by W.R. Meadows, or equal.
2.1.20 Vapor Retarder, where shown or specified, shall be “Moistop” as manufactured by Fortifiber Corp. Vapor Barrier shall be “Premoulded Membrane Vaporseal” as manufactured by W.R. Meadows, or equal.
2.1.21 Perimeter Insulation, where shown or specified, shall be “Styrofoam Square Edge” as manufactured by the Dow Chemical Corporation, “Foamular 250” as manufactured by UC Industries, or equal.
2.1.22 Penetrating Sealer, where shown or specified, shall be two components, 50% solids penetrating epoxy sealer. The penetrating sealer shall be fully compatible with the types of form oil, curing compound and joint sealant used.
3.08 03300-6 SECTION 03300
CAST-IN-PLACE CONCRETE
2.1.22.1 Concrete surfaces to be treated must be dry, cured for a minimum of 21 days, free from surface accumulations of dust, dirt, oil, debris, concrete curing compounds, bond breakers, or other compounds which would prevent penetration and intimate contact between the concrete surface and the penetrating sealer. Concrete surfaces require preparation per manufacturer’s directions prior to sealer installation.
2.1.22.2 Penetrating sealer shall be “Spec-Seal” as manufactured by Conspec, Inc., or equal.
2.1.23 Metal Slab Joints, where shown or specified, shall be keyed type, minimum 18 gauge, galvanized steel by Heckmann Building Products, or equal.
2.1.24 Vapor Barrier: 6 mil (0.5 mm) thick clear polyethylene film type recommended for below grade application.
2.2 CONCRETE MIX DESIGN:
2.2.1 The Contractor shall submit concrete mix designs to be reviewed by the Engineer. The mix designs shall be confirmed by making and testing trial mixes for each class of concrete to be incorporated in the work. All testing shall be made by an approved testing laboratory at the expense of the Contractor. Mix designs shall conform to the ACI 301, except as may be modified in the Plans and/or Specifications.
2.2.2 No job concrete shall be poured until the mix design for that concrete has been approved by the Engineer. Once the mix has been approved, it shall not be changed, except when requested by the Engineer, or if requested by the Contractor and approved by the Engineer.
2.2.3 Ready-mixed concrete from an established company will be approved, if conforming to ASTM C94, and to this specification. All concrete shall be batched, mixed, delivered to the site, and shall conform to these requirements and be controlled in a manner to assure uniform concrete for the quality specified.
2.2.4 Water/cement ratios of all mixes shall be determined from w/c curve plotted from tests of the cement and aggregates used on the job. If necessary to increase the water content of the mix due to field conditions, sufficient cement must be added to maintain the design water/cement ratio. Accelerating or retarding admixtures may be permitted by the Engineer if requested by the Contractor to compensate for adverse weather conditions.
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2.2.4.1 The various classes of concrete shall be designated as follows:
MAXIMUM PERMISSIBLE WATER-CEMENT RATIOS FOR CONCRETE (WHEN STRENGTH DATA FROM TRIAL BATCHES OR FIELD EXPERIENCE ARE NOT AVAILABLE) Maximum permissible water-cement ratio
NON-AIR-ENTRAINED AIR-ENTRAINED MIN. 28-DAY CONCRETE CONCRETE CLASS COMPRESSIVE STRENGTH ABSOLUTE US GAL. PER ABSOLUTE US GAL. PER IN PSI* RATIO BY 94-LB. BAG RATIO BY 94-LB. BAG WEIGHT OF CEMENT WEIGHT OF CEMENT
A 5,000 ** ** ** **
B 4,000 0.44 5.0 0.35 4.0
C 3,000 0.58 6.6 0.46 5.2
D 2,500 0.67 7.6 0.54 6.1
E 2,000 0.71 8.0 - -
*28-day strength. With most materials, water/cement ratios shown will provide average strengths greater than indicated in Section 5.4 of ACI 318R as being required. **For strength above 4,500 psi (non-air-entrained concrete) and 4,000 psi (air-entrained concrete) proportions shall be established by methods of Section 5.3 of ACI 318R.
Unless otherwise specified, all concrete shall be Class “B”, non-air-entrained except exposed concrete which shall be air-entrained. When foundation walls or grade beams are exposed to weather above grade, the entire wall shall be considered exposed concrete.
2.2.4.2 Maximum size aggregates shall be used as follows unless otherwise designated by the Engineer.
1-1/2” general work 3/4" thin sections; heavy reinforcing 3/4” columns, beams and slabs Over 1-1/2” massive structures, with approval 3/8” floor toppings
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2.2.4.3 Slump - Maximum:
Reinforced concrete - general 4” Reinforced concrete - thin walls, columns 5” Non-reinforced concrete 3” Pavements, including sidewalks 3” Heavy mass concrete 3”
2.2.4.4 Air Content: Use an approved air entraining admixture. The entrained content shall be controlled between 4% - 6%. See Plans for concrete work requiring air entrainment.
2.2.4.4.1 For mixes containing coarse aggregate with a top size of 3/4” or smaller and for exposed concrete subject to frost and salt action, air contents shall be increased to the range of 5% - 7%.
2.2.4.5 Should the Contractor feel it advantageous to employ concrete additives to improve workmanship or facilitate his work, he shall obtain the approval of the Engineer prior to his use of additives.
2.2.4.6 Use of accelerating admixtures in cold weather will not relax cold weather placement requirements.
2.3 STORAGE OF MATERIALS:
2.3.1 Portland Cement shall be stored in a weather-tight structure. No cement that has taken a warehouse set shall be used and any stored over sixty (60) days shall be rejected unless tested for soundness and setting time under ASTM C150. Such tests shall be at the Contractor’s expense.
2.3.2 Fine and coarse aggregates shall be kept separated and free from deleterious substances. All topsoil shall be removed from the storage area. Materials shall be stockpiled in layers to prevent segregation; however, re-mixing may be required if gradation is not maintained. Care shall be taken not to inter-mix materials in the area with the aggregates.
2.3.3 Any materials that have deteriorated or become contaminated will be rejected for use in the concrete and must be promptly disposed of by the Contractor.
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PART 3 - EXECUTION
3.1 FIELD QUALITY CONTROL:
3.1.1 Before each pour, forms and reinforcing shall be inspected and approved by the Engineer. The Contractor shall give at least 24 hours notice before such an inspection is required. No pour shall be started until the Engineer has given approval. No concreting may be done in the absence of the Engineer without written permission of the Engineer.
3.1.2 Concrete Batch Ticket:
3.1.2.1 The Contractor shall require the manufacturer of the concrete to furnish to the Engineer with each batch of concrete before unloading at the site, a delivery ticket on which is printed, stamped, or written, information concerning said concrete as follows:
- Name of ready-mix batch plant - Serial number of ticket - Date - Truck number - Name of purchaser - Specific designation of job (name and location) - Designation of the concrete by compressive strength - Amount of concrete in cubic yards - Time loaded or of first mixing of cement and aggregates - Reading of revolution counter at the first addition of water - Type and brand, and amount of cement - Type and brand, and amount of admixtures - Total water added by producer (and W/C ratio) - Water added at job site (upon approval of the Engineer) - Maximum size of aggregate - Weights of fine and coarse aggregate - Ingredients certified as being previously approved - Signature or initials of ready-mix representative
3.1.3 Concrete Testing:
3.1.3.1 The Contractor shall employ an approved commercial testing laboratory at his own expense to provide field sampling, testing and inspection of all concrete. Continuous inspection by the approved testing laboratory shall be provided during all concrete pours. The Contractor
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shall maintain a record set of plans at the site showing date and amount of each pour, test results and temperature. If any portion of the work shows low test results, the Engineer may require batch plant inspection, additional testing, load tests, cored samples, and/or replacement of the faulty work, etc., at the Contractor’s expense.
3.1.3.2 The Contractor, through its approved testing laboratory, shall make all laboratory or field tests as required and shall furnish all necessary equipment. The Contractor, through its approved testing laboratory, shall transport all test cylinders from the site to the laboratory.
3.1.3.3 Field concrete inspection: The Contractor, through its approved testing laboratory, shall provide a competent field concrete inspector whose minimum duties shall be as follows:
- Check each truck on arrival to make sure that the concrete is not retempered.
- Make necessary slump tests for uniformity control.
- Make air tests and yield tests as required.
- Make any and all test cylinders as may be required in the Specifications.
- Notify the Engineers and/or his representative if any test results vary from the specified limits.
3.1.3.4 Tests:
a. Concrete shall be tested by an approved testing laboratory as follows:
- Standard 6” x 12” compression cylinders shall be in compliance with ASTM C39 in sets of four and shall be moist cured. Break 2 at 7 days, and 2 at 28 days. One set shall be made for approval of each mix design, one set for first pour of 50 cubic yards or less, and one set for each additional pour of 50 cubic yards. If less than 50 cubic yards are placed in one day, one set shall be made for each day’s pour.
- All test cylinders shall be cast, moist cured and broken under laboratory conditions in accordance with the ASTM C31 and ASTM C39. All four cylinders of a test shall be taken from the middle third of a single load. Each cylinder shall be properly labeled with an identifying mark, the mix proportions, air content, amount of water, slump, and the location in the structure where the concrete was
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placed. Test reports shall include all this information. Distribute copies of reports as requested by the Engineer. Should any results be questionable, the Engineer shall be notified immediately so that corrective measures can be taken. Any test cylinder which has broken and fails to meet requirements shall be preserved for inspection by the Engineer.
3.1.4 Records:
3.1.4.1 Maintain records of concrete placement. Record date, location, quantity, air temperature and test samples taken.
3.2 BATCHING AND MIXING:
3.2.1 All Batching and Mixing shall conform to the following and the ACI 304, “Recommended Practice for Measuring, Mixing, Transporting and Placing Concrete”.
3.2.2 Aggregates and bulk cement shall be measured to within 1% by weight. Cement in standard sacks need not be weighed. Water shall be measured by volume or by weight to within 1/2%. Aggregate weights shall be corrected for moisture content. Admixtures shall be added through appropriate dispensing equipment to an accuracy of 3%.
3.2.3 The complete plant assembly shall be approved by the Engineer and shall conform to the following requirements:
- Provide ready adjustment of aggregate weights for varying moisture contents.
- Provide means of accurately controlling and easily checking water-cement ratio.
- Provide accurate control of all materials with positive shut-off.
- Facilities shall be provided for prompt removal of excess materials in hoppers.
- Each specified size of aggregate shall be measured separately with a separate beam scale.
- Bulk cement shall be dropped through canvas drop chutes or telescopic flexible hose tremie.
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3.2.4 Concrete mixers or mixer trucks shall not be loaded to more than the rated capacity of the truck.
3.2.5 All concrete shall be mixed not less than 60 revolutions in the drum of a modern power mixer, at the rated speed of rotation. Mix not less than an additional 30 revolutions after the addition of any further water to the mix.
3.2.6 Do not add raw materials to the drum until all of the preceding batch has been discharged. For transit mixers, the wash water shall be discharged and not used as part of the mix water for the next batch.
3.2.7 Transit-mixed concrete shall be transported to the job site unmixed and only after arrival at the job site shall mixing begin. All concrete shall be unloaded from the mixer within 45 minutes after completion of mixing. All concrete still remaining in the truck shall be rejected.
3.2.8 The total time interval from the time the cement makes contact with the aggregate to the complete unloading from the mixer shall not exceed 90 minutes, unless such time is extended by the Engineer. The time may be reduced in hot weather or under unusual conditions, if unsatisfactory results are obtained.
3.3 FORMWORK:
3.3.1 The Contractor shall design and construct suitable and adequate formwork in conformance with ACI 347R. All shoring shall be properly braced to safely withstand all vertical, moving and lateral forces during the construction period. Responsibility for adequacy and safety rests with the Contractor. Materials shall be as stated in Paragraph 2.1.
3.3.2 General requirements for all forms shall be as follows:
- Forms shall be constructed of wood, plywood, or steel.
- All forms shall be set true to line, plumb, and properly braced so as to maintain the desired position and shape during and after pouring concrete. Forms shall be sufficiently tight to prevent leakage.
- All joints between sheets shall be backed up to assure that both sheets are in the same plane. Edges of abutting sheets shall be straight and true and shall be forced tightly together to minimize fins. Quality of form contact surfaces shall be subject to Engineer’s approval.
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- Form ties shall be designed for the specific wall thickness required, and after removal of the external portion, no metal shall remain closer than one inch (1”) from the surface. Ties to be left in place shall be equipped with washers or other approved devices to prevent seepage of moisture along the tie. The removable portion shall be oil or grease coated.
- Immediately following the removal of forms, the projecting ties shall be removed and all holes filled with grout flush with the wall. Care shall be taken to use the same brand of cement and same mix proportions used in the wall to prevent color differences.
- Forms for walls and columns shall be provided with removable cleanout panels, to allow removal of chips and debris. All plywood forms must be new when first used on this job, but may be reused if kept in good condition. All forms shall be swept or flushed clean of shavings, debris, and other loose material. Loose earth and rock shall be scraped from footing trenches before pouring concrete.
- Provide 3/4" chamfer strips, unless noted otherwise on the drawings, at all exposed corners of columns, beams and walls where later finish is not to be applied.
- All forms and shores for floor and roof slabs and beams shall be “crowned” or “cambered” 1/4" for each 12 feet of span to eliminate dead load deflection. All forms shall be oiled with a non-staining mineral form oil before placing reinforcing.
- Build into forms all hangers, anchors, bolts, inserts, sleeves, etc., required to be set as part of this work, place and secure in exact position.
3.3.3 Form removal shall be as follows:
3.3.3.1 It shall be the Contractor’s responsibility to determine the time at which forms may be removed without endangering the structure, subject to the following limitations, unless documentation is provided to modify these requirements:
Footing forms - 24 hours minimum; continue curing as specified.
Wall forms - 2 days minimum for ten (10) feet high. Add one (1) day for each additional five (5) feet of height; continue curing as specified.
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Superstructure slabs, beams and columns shall not be stripped until the concrete attains at least 75% of its design strength as proven by test cylinders, and until a minimum of 14 days has elapsed.
Reshoring - immediately after stripping, fully reshore all slabs which are to be used to support shores for upper slabs. All forms for upper floor pours must be supported by shoring to at least two levels of full strength concrete.
3.4 JOINTS FOR CONCRETE:
3.4.1 Joints for concrete shall include all expansion joints, construction joints and contraction joints.
3.4.2 All joints shall be constructed at locations shown on the drawings, or as directed by the Engineer. Additional joints may be constructed by the Contractor subject to the approval of the Engineer.
3.4.3 Expansion Joints:
3.4.3.1 Expansion joints shall be constructed where shown and as directed. Reinforcement, corner protection angles or other fixed items embedded or bonded into concrete shall not be run continuously through expansion joints. Reinforcement shall be discontinued 2 inches from the joint face. A slightly rounded edging shall be provided to finish neatly all edges around expansion joints.
3.4.3.2 Preformed expansion joint filler material, sealant and waterstops, where shown on the drawings, shall be as specified in Paragraph 2.1.
3.4.4 Construction Joints:
3.4.4.1 The location of construction joints shall be chosen by the Contractor and shall be subject to the Engineer’s approval except where specifically located on the Plans.
3.4.4.2 Horizontal construction joints in walls will not be permitted, except with the approval of the Engineer. In order to minimize shrinkage, long continuous walls shall not be poured at one time. No more than 50 feet in horizontal direction shall be poured without a construction joint, unless prior approval is obtained from the Engineer.
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3.4.4.3 Reinforcing shall be discontinuous through a construction joint, unless otherwise noted on drawings. As shown or specified on the drawings, additional No. 3 reinforcing bars spaced at 12-inches on center shall be placed horizontally in each construction joint at the center of the section. These bars shall be 4-feet long and shall extend 2-feet on each side of the joint. Reinforcement projecting through joint shall be kept clean.
3.4.4.4 As indicated on the drawings, all construction joints shall be provided with a keyway and a PVC waterstop as specified in Paragraph 2.1. The joint surface of the concrete previously placed shall be cleaned of all foreign matter and laitance by means of sandblasting with steam and sharp sand, or by other approved methods, until coarse aggregate is exposed. The concrete surface shall be saturated for a period of 6 hours and excess water then removed.
3.4.4.5 The new concrete shall be preceded by about 1/2-inch of soft mortar of the same proportions as that in the concrete. When accessible, this shall be scrubbed into the surface of the joint with wire brooms. When waterproofing is required, the entire joint shall be parged with a grout of approved mixture as recommended by the manufacturer of the waterproofing admixture, or one composed of one part integral waterproofing, three parts water and sufficient Portland Cement to form a thick, creamy mixture. This grout shall be fresh when followed by the new concrete. In column forms and deep narrow forms, the concrete placement shall be started with an oversanded mix with 5/8-inch maximum aggregate, and extra sack of cement per cubic yard, and a 5-inch slump. This mix shall be placed maximum 2 inches deep on the construction joint. A mortar layer shall not be used.
3.4.4.6 As indicated on drawings, a metal keyed floor slab joint may be used in lieu of above method.
3.4.5 Contraction (Control) Joints:
3.4.5.1 Contraction joints shall be located as shown on the drawings or as directed. Reinforcement through the joint shall be continuous as shown on the drawings and/or as directed by the Engineer.
3.4.5.2 Sawcut contraction joints (Type “A”) shall be made by cutting the concrete surface and filling with the sealant material as specified under paragraph 2.1. Cutting shall be done after the surface is firm enough not to be damaged by the cutting blade. Time of cutting shall be approved by the Engineer.
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3.4.5.3 Formed contraction joints (Type “B”) shall be made by tooling with a 1/4-inch radius edging tool and filled with the sealant material as specified under paragraph 2.1.
3.4.5.4 Premolded Contraction Joints (Type “C”) shall be “Kold-Seal Zipper Strip” by Vinylex or “Zip Cap Control Joint” by Greenstreak Products, or equal.
3.4.5.5 As indicated on drawings, a metal keyed floor slab joint may be used in lieu of above method.
3.5 INSERTS AND SLEEVES:
3.5.1 The Contractor shall cooperate with all other Contractors in permitting the placing of all necessary sleeves, conduit, or inserts for hangers for their trades. The Contractor shall notify the trades of all pours in ample time for the responsible Contractor to place all embedded items, sleeves, slots, holes or chases.
3.5.2 Accurately set all slots, chases, anchor bolts, opening, etc. All inserts for hanging mechanical equipment shall be provided and set by the Contractor for the trade involved. All sleeves for piping passing through floors and walls shall be provided by the Contractor for the trade involved and set by the General Contractor.
3.5.3 All conduit which must be placed in concrete slabs shall be installed after, and above the bottom reinforcing, but before, and under the top reinforcing. Where conduit cross-overs are necessary, they shall be located so that reinforcing is not displaced from its specified position.
3.5.4 All anchor bolts for the structural steel shall be carefully set as shown on the fabricator’s approved anchor bolt plan.
3.5.5 If, in the judgement of the Engineer, embedded items are located or grouped in a manner that will weaken the structure, the Contractor shall take the necessary corrective steps.
3.5.6 All inserts and sleeves where the outside diameter is greater than the spacing between the reinforcing steel, the reinforcing bars shall be warped around such inserts and sleeves. Unless shown otherwise on the drawings, provide, as a minimum, two #4 diagonal bars per face at 90 degrees to each other all around the inserts and sleeves.
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3.5.7 Where openings are left in new concrete or are made in existing concrete for the insertion of wall castings, pipes or other fixtures, the space around these fixtures shall be made watertight by completely filling with a non-shrinking concrete containing an admixture of “SikaSet-C”, “Anti-Hydro” Concrete Waterproofing Agent, or equal.
3.6 CONVEYING AND PLACING CONCRETE:
3.6.1 The placing or depositing of all concrete shall be done in accordance with ACI 304, and as modified herein.
3.6.2 Preparation Prior to Placing Concrete:
a. Prepare previously placed concrete surfaces by cleaning with steel brush and applying bonding agent in accordance with manufacturer=s instructions.
b. In locations where new concrete is dowelled to existing work, drill holes in existing concrete, insert steel dowels and pack solid with non-shrink grout. c. Before placing concrete, all debris, water, snow and ice shall be removed from places to be occupied by concrete. Wood forms shall be wetted except in freezing weather or oiled, and the reinforcement cleaned of ice or other coatings.
3.6.3 Conveying, transporting, and placing shall be done as rapidly as practicable and without segregation, loss of ingredients, and without unnecessary rehandling. The tempering of concrete will not be permitted.
3.6.4 Concrete shall be deposited as nearly as practical to its final position to avoid segregation due to rehandling or flowing. The concreting shall be carried on at such a rate that the concrete is at all times plastic and workable and flows readily into the spaces between the reinforcing bars. No concrete that has partially hardened or been contaminated by foreign material shall be deposited on the work, nor shall retempered concrete be used. Once the concreting is started, it shall be carried on as a continuous operation until the placing of the panel or section is completed. All concrete shall be compacted by suitable means during the placing operation, and thoroughly worked around reinforcement and embedded fixtures and into corners of the forms. Tremies shall be used for deep forms, and concrete shall not be dropped more than 6’-0”.
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3.6.5 Vibrating:
3.6.5.1 During and immediately after depositing, all concrete shall be thoroughly compacted by vibrating the concrete internally with mechanical vibrating equipment. Care must be taken not to over-vibrate the concrete. Maintain spare vibrator(s) at the site for use in the event of breakdowns.
3.6.5.2 Spade and work the coarse aggregate away from forms, and work concrete around reinforcement to avoid air pockets, voids, and honeycombed sections. Hand spading slabs will be required in addition to mechanical vibration.
3.6.6 During concreting, check shoring frequently with level. Strengthen or adjust shoring as required. Ensure reinforcement, inserts, embedded parts and formed joints are not disturbed during concrete placement.
3.6.7 Placing of concrete in supported elements shall not be started until the concrete previously placed in columns and walls is no longer plastic and has been in place at least two hours.
3.6.8 Screed all work to level surfaces at the proper elevations. Rake surfaces to provide bond for floor finishes where specified.
3.6.9 No concrete shall be deposited under water without written permission of the Engineer and then only in accordance with his directions. Proper tremie equipment and techniques must be used, should the need arise.
3.6.10 The Contractor shall have available at all times sufficient approved materials such that, when started, concrete shall be continuous operation until placement of panel or section is complete. Should placing of concrete be suspended or unavoidably interrupted once a pour has been started, provide bulkheads and keyways at formed surface at which to stop pour.
3.6.11 All laitance shall be removed from previous pours before additional concrete is placed.
3.6.12 Place concrete continuously between predetermined expansion, control and construction joints.
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3.7 PROTECTION AND CURING:
3.7.1 All concrete shall be protected against injury by sun, rain, freezing, mechanical damage, or premature drying. All concrete shall be maintained above 50oF in a moist or wet condition for at least the first 7 days after placement.
3.7.2 On vertical surfaces keep forms on, or cover with burlap blankets, kept wet. When forms are exposed to the sun, minimize moisture loss by keeping the forms wet until they can be removed safety.
3.7.2.1 For the preservation of moisture, apply one of the following procedures to concrete not in contact with forms, immediately after completion of placement and finishing:
a. continuous sprinkling b. application of absorptive mats or fabric kept continuously wet c. application of waterproof sheet materials as specified in Part 2, herein d. application of the curing agent specified in Part 2, herein
3.7.3 On horizontal surfaces and floors to receive later finishes, cover with wet burlap, wet sand, or curing paper and keep saturated. Cement finish floors shall be covered with protective covering material with lapped and sealed edges after the concrete has set sufficiently to carry worker’s weight. Covering shall remain in place until floor is cleaned. Weight covering with planks as required to hold it in place.
3.7.4 Cold weather protection shall conform to A.C.I. 306R, except as modified herein.
3.7.4.1 Prior to pouring, it shall be the Contractor’s responsibility to keep the forms free from snow, ice, mud or debris at all times, by means of covers, enclosures, live steam or heating below the forms, as necessary. Use of torches, open flames, salts, straw, hay or chemical is prohibited.
3.7.4.2 When air temperature is 40oF, or less, use only heated concrete, delivered to the forms at temperatures between 65oF and 85oF. All portions of freshly poured concrete shall be continually maintained at a temperature of not less than 50oF for seven days. Specified temperature shall be maintained by heated enclosures, insulating blankets, insulated forms, or whatever approved methods are required to attain the specified result.
3.7.4.3 Concrete shall not be poured on frozen soil. After pouring, protect against freezing and heaving of subgrade. Any frozen concrete will be rejected and removed at the Contractor’s expense. Accelerating admixtures shall not be accepted in lieu of winter protection.
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3.7.5 Hot weather protection shall conform to ACI 305R, except as modified herein.
3.7.5.1 During warm dry weather special care and precautions should be taken to prevent premature setting which may cause shrinkage and surface checking. No concrete shall be placed at temperatures above 90oF without approval of the Engineer.
3.7.6 No water (except curing spray) shall be allowed to come in contact with the concrete or masonry surface for a minimum of 24 hours. Should the rising water place a stress on the concrete, proper bracing shall be provided. Loading shall not occur without prior approval by the Engineer, and proper safety precautions shall be the responsibility of the Contractor.
3.7.7 Curing compound may be used as specified in Paragraph 2.1 provided discoloration does not occur and application is in accordance with manufacturer’s direction and is compatible with concrete finish.
3.8 FOOTINGS AND MATS:
3.8.1 Hand trim excavation to required levels.
3.8.2 Where shown on the drawings provide concrete mud mat to the thickness indicated.
3.8.3 Support reinforcing on bricks or precast blocks, or where mud mat is used, on chairs or bolsters, 3” clear of soil.
3.8.4 Columns and wall dowels shall be positioned, supported and tied in place before concrete is poured. Footing bottoms shall be inspected and approved by the Engineer before placing mud mat or footings.
3.9 SUPPORTED SLABS ON FORMS:
3.9.1 Forms shall be built to required dimensions and camber as specified above. Reinforcing shall be located as shown on approved placing plans. Support bars at specified heights with bolsters, chairs, etc., so that reinforcing will not be moved from the specified position during placing of concrete.
3.9.2 Refer to paragraph 3.5 for installation of conduits.
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3.10 SLABS ON GROUND:
3.10.1 Subgrade and base to be prepared as specified in Contract Documents.
3.10.2 Form depressed ribs under partitions as required by sloping gravel, or provide permanent side forms to retain gravel.
3.10.3 Trench subgrade for electric conduit as detailed on Plans. All reinforcing shall be above electric conduit.
3.10.4 Place slabs of thickness shown on Plans, vibrate, screed, float level, and finish as specified below.
3.11 CONCRETE FINISHES - FORMED SURFACES:
3.11.1 After the forms are removed, all concrete surfaces shall be inspected, and any poor joints, voids, stone pockets or other defective areas noted by the Engineer shall be repaired immediately at the Contractor’s expense by cutting away the unsound area to a minimum depth of 1 inch, and refilling with mortar mixed using the same brand of cement as the original pour. Edges of the patch shall be square with the face, with feather-edging prohibited. Obtain approval of corrective action prior to repair.
3.11.2 Care shall be taken to saturate the patched area and holes shall be filled in 1/2-inch layers with a delay for an initial set to take place before the succeeding layer is applied. If, in the opinion of the Engineer, improper consolidation is too extensive, or if the structure appears weakened by the voids, complete removal of the concrete in question may be required. Patches shall be kept moist for a minimum of three days.
3.11.3 Rubbed finishes shall be as follows:
a. Type A: Surfaces shall be rubbed until all marks are obliterated and a uniformly smooth finish is obtained.
b. Type B: Surfaces shall be rubbed until they are uniformly smooth, but the complete obliteration of all marks is not required.
c. Type C: All fins, burrs and projections shall be removed, any honey- comb or tie-holes shall be filled and patched.
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3.11.4 The type of finish to be used shall be as scheduled or as noted on the Plans. Where the type of finish is not shown or scheduled, exposed faces shall be given a Type B finish and unexposed faces shall be given Type C finish.
3.11.5 Rubbing shall begin as soon as practicable after removal of forms and shall be expedited to completion as rapidly as practicable.
3.11.6 Surfaces shall be rubbed with carborundum and water until all fins, bubbles, hollows and other defects are removed. Grout or mortar shall not be used in the rubbing process, and plastering of surfaces will not be permitted. Power tools shall be used for rubbing with hand work limited to inaccessible corners or very small areas.
3.12 FLOOR AND SLAB FINISHING:
3.12.1 Finished floors and slabs shall be level to within 1/8” of finish floor elevation in ten feet. If this variation occurs, it must not be abrupt, but must taper so that the 1/8” variation takes place in not under 4 feet. Areas with drains shall have the surfaces sloped uniformly and true to the effect that no surface ponding occurs. If required by the Engineer, replace, grind or furnish underlayment to correct the variation, at the Contractor’s expense. All floors and slabs shall be cured and protected as specified.
3.12.2 Trowelled Finish: Provide a floated finish, followed by a power troweling and then a hand troweling thoroughly consolidating the surface. Provide a finished surface essentially free from trowel marks and uniform in texture and appearance.
3.12.2.1 Where exposed concrete finish is specified, provide a steel trowelled finish.
3.12.2.2 Under quarry tile and ceramic tile screed to accurate lines and levels as required to receive these materials. Floors receiving tile are to be steel trowelled finished and are indicated on the Plans.
3.12.3 Float Finish: A float finish shall be applied to all exterior concrete and those areas not intended for occupancy, such as culvert inverts, bottoms of manholes and catch basins, pads, etc.
3.12.4 Broom Finish: Provide a floated finish. While the surface is still plastic, provide a textured finish by drawing a fiber bustle broom uniformly over the surface in one direction only. Provide “medium” texturing unless noted otherwise on the Contract Drawings. Sidewalks, walkways, or exterior ramps shall be given a broom finish, perpendicular to traffic, sufficient to leave marks without appreciable disturbance of the surface.
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3.12.5 Dusting with dry cement or cement sand mixtures, to hasten drying, is prohibited. Dry time shall be controlled by controlling the water content and slump of the concrete when placed.
3.13 BONDING:
3.13.1 For the bonding of new and old concrete, such provisions shall be made by means of steps, dovetails, bonding agents as specified in Paragraph 2.1, or other devices as shown, or directed.
3.13.2 When placing of concrete is suspended or unavoidably interrupted, all necessary grooves for bonding future work shall be made before the concrete has attained its initial set. When the work is resumed, concrete previously placed shall be roughened, cleaned of all foreign material and laitance by means of sandblasting with steam and sharp sand or other approved methods, until coarse aggregate is exposed, and thoroughly wetted and slushed with mortar containing the same proportion of cement and fine aggregate as used in the concrete to be placed. Follow manufacturer’s preparation recommendations when using a bonding agent.
3.14 MISCELLANEOUS CONCRETE WORK:
3.14.1 Pour all sump pits, canopies, copings and provide all other miscellaneous concrete and cement work shown on the drawings. All such concrete shall be reinforced as shown. Provide all cement filled stair treads as detailed. Place bottoms and walls of pits and trenches monolithically or provide waterstops and keys.
3.14.2 Concrete Walks: Provide 4 inches thick minimum. Provide contraction joints spaced every 5 linear feet, unless otherwise indicated. Cut contraction joints 3/4-inch deep with a jointing tool after the surface has been finished. Provide 1/2-inch thick transverse expansion joints at changes in direction, where sidewalk abuts curb, steps, rigid pavement, or other similar structures. Provide a transverse slope of 1/4-inch per foot, and limit variation in cross section to 1/4-inch in 5 feet unless otherwise indicated.
3.14.3 Curbs and Gutters: Provide contraction joints spaced every 10 feet maximum, unless otherwise indicated. Cut contraction joints 3/4-inch deep with a jointing tool after the surface has been finished. Provide expansion joints 1/2-inch thick and spaced every 100 feet maximum, unless otherwise indicated. Provide a broom finish.
3.14.4 Equipment Bases: Unless otherwise shown, all equipment shall be erected on bases of Class “B” concrete. Thickness shall be as noted on the Plans, but at no time shall it measure less than 1 inch.
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CAST-IN-PLACE CONCRETE
3.14.5 Concrete Stairs, Steps and Platforms: Stairs, steps and platforms shall be formed to required profiles shown on the Plans. Place reinforcing as required. Finish of stairs and steps shall be monolithic. Where shown on Plans, provide for nosings. Exterior stairs, steps and platforms shall have a non-slip finish. Before final troweling, embed abrasive grits, as specified in Paragraph 2.1, in the surface.
3.15 CEMENTITIOUS COATING:
3.15.1 Cementitious Coating shall be applied to all exposed exterior and interior Cast-In- Place Concrete surfaces except concrete floors and walking surfaces in accordance with the schedule shown on the Plans, or otherwise directed.
3.15.2 The surfaces to be coated shall be clean, free of all laitance, dirt, grease, curing compound, form treatments, efflorescence, paint and other foreign matter. All formed tie-rod holes and honeycombed areas shall be patched flush with the surrounding area using mortar as recommended by cementitious coating manufacturer.
3.15.3 All areas scheduled to be coated will receive two coats of cementitious coating as specified in Paragraph 2.1, applied at a minimum rate of 2 pounds per square yard per coat. The first coat shall be allowed to set before the second coat is applied. Sufficient materials shall be applied to fully seal all pores and voids. All coatings shall be done strictly in accordance with the manufacturer’s recommendations.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - CAST-IN-PLACE CONCRETE:
4.1.1 The quantity of Cast-In-Place Concrete for which payment will be made will be the actual number of cubic yards measured in place within the lines shown, specified, or ordered.
4.2 PAYMENT - CAST-IN-PLACE CONCRETE:
4.2.1 For Cast-In-Place Concrete, not included in other unit or lump sum price items, payment for Cast-In-Place Concrete will be made at the applicable price stated in the Bid.
END OF SECTION
3.08 03300-25 SECTION 04200
UNIT MASONRY
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Unit Masonry, including accessory items of work herein described, as shown on the Plans, as specified and/or directed.
1.2 APPLICABLE SPECIFICATIONS, CODES AND STANDARDS:
1.2.1 Reference to standard specifications for the following organizations is intended to specify minimum standards for quality of materials and performance of workmanship, and for standard test methods.
a. American Society for Testing and Material (ASTM) Latest Edition.
b. American Concrete Institute (ACI) and American Society of Civil Engineers (ASCE), Building Code Requirements For Masonry Structures, Latest Edition.
c. National Concrete Masonry Association (NCMA) Specifications, Latest Edition.
1.3 SUBMITTALS: Submit the following.
1.3.1 Design Data:
a. Mortar mix design (submit testing data if not pre-mixed)
b. Grout mix design
1.3.2 Manufacturer's Catalog Data:
a. Masonry accessories
b. Reinforcement
c. Pre-mixed mortar
d. Control joints
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e. Expansion joints
f. Water-repellent admixture
g. Flashing
h. Grout
Submit for each type.
1.3.3 Drawings:
a. Reinforcing steel
b. Accessories
Indicate splicing, laps, shapes, dimensions, and details of reinforcing bars and accessories. Include details of anchors, adjustable wall ties, positioning devices, bond beams, and lintels. Do not scale drawings to determine lengths of bars.
1.3.4 Manufacturer's Instructions:
a. Masonry cement
If masonry cement is used, submit the manufacturer's printed instructions on proportions of water and aggregates and on mixing to obtain the type of mortar required.
1.3.5 Samples:
a. Masonry units
b. Mortar colors
c. Wall reinforcement
d. Anchors
e. Wall ties
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UNIT MASONRY
Submit five representative full size masonry units showing full range of color, texture, finish, and dimensions, two samples of each color of mortar, and two samples of each type of wall reinforcement, anchor, and wall tie.
1.3.6 Sample Panel:
a. Masonry panel
At the job site submit for approval by the Engineer, a sample masonry panel approximately 6 feet long by 4 feet high showing the workmanship, coursing, bond, weep holes, flashing, thickness, anchors, joint reinforcing, wall ties, rigid-board insulation, intersection of walls, bond beams, expansion and control joint, and tooling of joints, range of color, texture of masonry, and mortar color.
1.3.7 Factory Test Reports:
a. Efflorescence test
Submit efflorescence test reports on masonry units that are to be exposed to weathering. Schedule tests far enough in advance of starting masonry work to permit retesting if necessary. Test five pairs of specimens of each type of masonry unit for efflorescence in accordance with ASTM C67. If any pair is rated "effloresced," reject the units represented by the samples.
1.3.8 Certificates of Compliance: The Contractor shall submit to the Engineer prior to delivery, manufacturer's or supplier's certification of compliance of units with specified standards, as determined by an acceptable testing agency conforming to the applicable requirements of ASTM.
a. Masonry cement
b. Grout
c. Mortar
d. Compressive strength tests for block
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1.4 QUALITY ASSURANCE:
1.4.1 Appearance: Do not change source or supply of materials after the work has started if the appearance of the finished work would be affected. Units should be sound and free from cracks or other defects that would interfere with proper setting, impair strength and performance of construction, or be objectionable in appearance.
1.5 DELIVERY, STORAGE, AND HANDLING: Deliver cementitious materials to the site in unbroken containers, plainly marked and labeled with manufacturers' names and brands. Store cementitious materials in dry, weathertight sheds or enclosures and handle so as to prevent entry of foreign materials and damage by water or dampness. Store masonry units off the ground and handle with care to avoid chipping and breakage. Protect materials from damage and, except for sand, keep dry until used. Cover sand to prevent intrusion of water and foreign materials and to prevent drying. Do not use materials containing frost or ice.
1.6 ENVIRONMENTAL CONDITIONS:
1.6.1 Cold Weather Construction: During cold weather, that is when the air temperature is below 40 degrees F and falling, or when it appears that the air temperature will drop to 40 degrees F or below within 24 hours, do not lay masonry unless the work is protected from freezing as specified below. Surfaces receiving mortar shall be free of ice and frost. Comply with the requirements specified below for the respective air temperatures:
a. Air Temperature 40 to 25 Degrees F: Heat sand or mixing water to produce mortar temperature between 40 and 120 degrees F.
b. Air Temperature 25 to 20 Degrees F: Heat sand and mixing water to produce mortar temperature between 40 and 120 degrees F. Use salamanders or other heat sources on both sides of walls under construction. Use windbreaks when wind is in excess of 15 mph.
c. Air Temperature 20 Degrees F and Below: Heat sand and mixing water to produce mortar temperature between 40 and 120 degrees F. Provide enclosures and auxiliary heat to maintain air temperature above 32 degrees F on both sides of walls under construction. Ascertain that temperatures of masonry units are not less than 20 degrees F when units are laid.
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1.6.2 Cold Weather Protection: Protect newly laid masonry as specified below for the respective mean daily air temperature (MDAT), that is, the average of the daytime high temperature and the forecasted nighttime low temperature.
a. MDAT 40 to 25 Degrees F: Protect masonry from rain and snow by covering with weather-resistive membrane for 24 hours after laying.
b. MDAT 25 to 20 Degrees F: Completely cover newly-laid masonry with insulating blankets and weather-resistive membrane for 24 hours.
c. MDAT 20 Degrees F and Below: Maintain temperature of masonry above 32 degrees F for 24 hours by providing enclosures and supplementary heat or other approved means.
1.7 SCHEDULING: Coordinate masonry work with the work of other trades to accommodate built-in items and to avoid cutting and patching.
PART 2 - PRODUCTS
2.1 MASONRY UNITS:
2.1.1 Concrete Masonry Units: Units shall be of modular dimensions and be steam cured, or approved equal. Exposed surfaces of units shall be comparatively smooth and of uniform texture. Exterior concrete masonry units shall have water-repellant admixture added during manufacture. Concrete masonry units in firewalls shall conform to the requirements of Underwriters Laboratories, Inc. (UL), Design No. U904.
a. Hollow Load-Bearing Units: ASTM C90, made with lightweight aggregate. Provide load-bearing units for exterior walls, foundation walls, load-bearing walls, and shear walls. Minimum compressive strength shall not be less than 1900 psi.
b. Hollow Non-Load-Bearing Units: ASTM C129, made with lightweight aggregate. Load-bearing units may be provided in lieu of non-load-bearing units.
c. Concrete Building Brick: ASTM C55, made with lightweight aggregate. Concrete brick shall match the concrete masonry units as closely as practicable in color and surface characteristics.
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d. Solid Load-Bearing Units: ASTM C90, made with lightweight aggregates. Provide solid units for masonry bearing under structural framing members.
e. Special Shapes: Provide special shapes such as closures, header units, and jamb units as necessary to complete the work. Special shapes shall conform to the requirements for the units with which they are used.
2.1.2 Precast Concrete Lintels: Same surface texture as adjacent masonry units, with a 28-day compressive strength of not less than 2000 psi. Provide reinforcing as indicated with a minimum of one No. 4 bar per 4-inch width top and bottom. Provide lintels of sizes indicated, straight and true, with at least 8 inches of bearing at each end.
2.1.3 Flue Linings and Thimbles: ASTM C315, free from fractures, large or deep cracks, blisters, and other defects. Sizes and shapes shall be as indicated.
2.1.4 Water-Repellant Admixture: Polymeric type formulated to reduce porosity and water transmission. Construct panels of masonry units and mortar which contain the water-repellant admixture. When tested in accordance with ASTM E72, such panels shall be flexural strength not less than 20 percent greater, and compressive strength not less than 3 percent greater, than similar panels which do not contain the admixture. When tested in accordance with ASTM E514, panels shall exhibit no water visible on back of test panel and no leaks through the panel after 24 hours, and not more than 25 percent of wall area shall be damp after 72 hours.
2.2 MORTAR:
2.2.1 Portland Cement: ASTM C150, Type I, II, or III.
2.2.2 Hydrated Lime: ASTM C207, Type S.
2.2.3 Masonry Cement: ASTM C91, except that for masonry cement used in mortar for exterior walls, the air content of the mortar specimen shall be not more than 16 percent by volume in lieu of 22 percent. Containers shall bear complete instructions for proportioning and mixing to obtain the required types of mortar.
2.2.4 Sand: ASTM C144.
2.2.5 Water: Clean, potable, and free from substances which could adversely affect the mortar.
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2.2.6 Mortar Types: ASTM C270, Type M for foundation walls, bearing walls, exterior walls; Type N or S for non-load-bearing, non-shear-wall interior masonry; and Type S for all other masonry work; except where higher compressive strength is indicated on structural drawings. Air content shall be limited to 12 percent. Mortar in firewalls shall conform to the requirements of Underwriters Laboratories, Inc. (UL), Design No. U904.
2.2.7 Pre-Mixed Mortar: ASTM C270, Type N, compressive strength of 750 psi in 28 days. Air content shall be limited to 12 percent.
2.2.8 Admixtures: No air-entraining admixtures, anti-freeze compounds or calcium chlorides shall be included in mortar. Where colored mortar is indicated, add pigment to obtain the color indicated. Mortar colors shall consist of inorganic compounds not to exceed 15% of the weight of the cement. Admixtures may be used in mortar to retard curing and provide up to 36 hours of workability, provided the admixture does not adversely affect bonding or compressive strength.
2.3 GROUT:
2.3.1 Grout for reinforced masonry shall be proportioned and mixed in accordance with ASTM C476. Fine grout (with sand aggregate) shall be used in grout spaces where minimum horizontal dimension is less than 4 inches. Coarse grout (with pea gravel) may be used elsewhere. Samples shall be tested in accordance with applicable portions of ASTM C1019 and shall exhibit a minimum ultimate compressive strength of 2500 psi at 28 days. Do not use admixtures that contain calcium chlorides, air-entrainment or antifreeze compounds.
2.4 ACCESSORIES:
2.4.1 Horizontal Joint Reinforcement: Fabricate from cold drawn steel wire, ASTM A82. Wire shall be hot-dipped galvanized after fabrication in accordance with ASTM A153 (1.5 oz of zinc per square foot). Reinforcement shall be truss type with two or more longitudinal wires welded to a continuous diagonal cross wire, or ladder type with perpendicular cross wires not more than 16 inches o.c. Provide flat sections 10 feet long, and preformed corners and tees approximately 30 inches long. Overall width shall be approximately 2-inches less than nominal thickness of wall.
2.4.1.1 Single-Wythe: For single-wythe walls and partitions, provide two 9-gauge (0.1483-inch) longitudinal wires and 9-gauge cross wires.
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2.4.2 Anchors and Ties: Provide approved designs of stainless steel, zinc-coated steel, or noncorrosive metal having the equivalent total strength of steel types. Zinc coat steel by the hot-dip process after fabrication to a minimum of 1.25 ounces of zinc per square foot of surface when tested in accordance with ASTM A90.
a. Corrugated Metal Ties: Not less than 7/8-inch wide by approximately 7 inches long and not lighter than 22 gauge.
b. Rigid Steel Anchors: Not less than 1-1/2 inches wide, 1/4-inch thick, and 24 inches long with each end bent not less than 2 inches.
c. Wire Mesh: Minimum 20 gauge, 1/2-inch mesh, galvanized wire, 1 inch less in width than width of masonry.
d. Dovetail Flat Bar or Wire Anchors: Flat bar: corrugated sheet steel, not lighter than 16 gauge, and 7/8-inch wide, with end turned up 1/4 inch. Wire: not lighter than 6 gauge, 7/8-inch wide with wire looped and closed. Dovetail slots and inserts are specified in Section 03300, "Cast-in-Place Concrete".
2.4.3 Fastenings: Build in bolts, metal wall plugs, and other metal fastenings furnished under other sections for securing furring and other items.
2.4.4 Reinforcing Bars: Vertical steel and dowel reinforcing shall be 60,000 psi and conform to ASTM A615 as specified in Section 03210.
2.4.5 Through-Wall Flashing: Provide one of the following types except that flashing indicated to terminate in reglets shall be metal or coated-metal flashing.
a. Coated-Copper Flashing: 5-ounce, electrolytic copper sheet, uniformly coated on both sides with acid-proof, alkali-proof, elastic bituminous compound. Factory apply coating to a weight of not less than 6 ounces per square foot (approximately 3 ounces per square foot on each side).
b. Minimum 5-Ounce Copper or Stainless Steel Flashing: Copper, ASTM B370, 6-ounce weight; stainless steel, ASTM A167, Type 301, 302, 304, or 316, 0.006-inch thick, No. 2 or No. 2D finish. Provide with factory-fabricated deformations that mechanically bond flashing against horizontal movement in all directions. Deformations shall consist of dimples, diagonal corrugations, or a combination of dimples and transverse corrugations.
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UNIT MASONRY
c. Plastic Flashing: Homogeneous, waterproof, impermeable, elastomeric sheeting not less than 0.030-inch thick. Sheeting shall have not less than 1000 pounds per square inch tensile strength, nor more than 7 percent tension set at 50 percent elongation when tested in accordance with ASTM D412. Suitably stabilize sheeting to resist exposure without visible deterioration when tested not less than 400 hours in accordance with ASTM D822. The material, after being exposed for not less than 1/2 hour to a temperature of minus 20 degrees F, shall show no cracking or flaking when, at that temperature, it is bent 180 degrees over a 1/32-inch diameter mandrel and then bent at the same point over the same size mandrel in the opposite direction 360 degrees and not be subject to rapid ultraviolet degradation.
d. Reinforced Membrane Flashing: Polyester film core with a reinforcing fiberglass scrim bonded to one side. The membrane shall be impervious to moisture, flexible, and not affected by caustic alkalis. The material, after being exposed for not less than 1/2 hour to a temperature of 32 degrees F, shall show no cracking when, at that temperature, it is bent 180 degrees over a 1/16-inch diameter mandrel and then bent at the same point over the same size mandrel in the opposite direction 360 degrees.
e. Embossed Membrane Flashing: Polyester film embossed in a small hexagon pattern, impervious to moisture and resistant to corrosion. Film shall not become brittle and shall remain flexible for thermal movements within wall.
2.4.6 Wicking for Weep Holes: Fiberglass, 1/4 inch in diameter, each piece not less than 18 inches long.
PART 3 - EXECUTION
3.1 PREPARATION:
3.1.1 Protection:
a. Stains: Protect exposed surfaces from mortar and other stains. When mortar joints are tooled, remove mortar from exposed surfaces with fiber brushes and wooden paddles. Protect base of walls from splash stains by covering adjacent ground with sand, sawdust, or polyethylene.
b. Loads: Do not apply uniform loads for at least 12 hours or concentrated loads for at least 72 hours after masonry is constructed.
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c. Provide temporary bracing as required to prevent damage during construction.
d. Polyester Embossed Film: Provide protective boards for polyester film during job installation to ensure no damage from building debris.
3.1.2 Surface Preparation: Surfaces on which masonry is to be placed shall be smooth, clean, and free of foreign substances when mortar is applied.
3.2 WORKMANSHIP: Carry masonry up level and plumb. Furnish and use story poles or gauge rods throughout the work. Changes in coursing or bonding after the work is started will not be permitted. Do not carry one section of the walls up in advance of the others. Step back unfinished work for joining with new work. Toothing will not be permitted. Check heights of masonry with an instrument at each floor and at sills and heads of openings to maintain the level of the walls. Build in door and window frames, louvered openings, anchors, pipes, ducts, and conduits as the masonry work progresses. Fill spaces around metal door frames solidly with mortar. Handle masonry units with care to avoid chipping, cracking, and spalling of faces and edges. Drilling, cutting, fitting, and patching to accommodate the work of others shall be performed by masonry mechanics. Cut masonry with masonry saws for exposed work. Structural steelwork, bolts, anchors, inserts, plugs, ties, lintels, and miscellaneous metalwork specified elsewhere shall be placed in position as the work progresses. Provide chases of approved dimensions for pipes and other purposes where indicated and where necessary. Inspect scaffolding regularly to ensure that it is amply strong, well braced, and securely tied in position. Do not overload scaffolding.
3.3 MORTAR MIXING: Measure mortar materials in 1 cu. ft. containers to maintain control and accuracy of proportions. Do not measure materials with shovels. Mix mortar in a mechanical batch mixer for not less than 3 nor more than 5 minutes after all ingredients are in so as to produce a uniform mixture. Add water gradually as required to produce a workable consistency. Do not load mixer beyond its rated capacity. Keep mortar boxes, pans, and mixer drums clean and free of debris and dried mortar. Retemper mortar which has stiffened because of evaporation by adding water and mixing to obtain a workable consistency. Do not use or retemper mortar which has not been placed in final position within 2-1/2 hours after the initial mixing. Do not use antifreeze compounds, salts, or other substances to lower the freezing point of mortar.
a. Mortar: Mix mortar in accordance with ASTM C270 to obtain type mortar required. When masonry cement is used, conform to printed mixing instructions of the masonry cement manufacturer. During mixing, add water-repellant admixture in quantity
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recommended by the admixture manufacturer to mortar which will be used in exterior concrete masonry unit walls.
b. Grout: ASTM C476. Provide fine grout in grout spaces less than 2 inches in any horizontal dimension or in which clearance between reinforcing and masonry is less than 3/4 inch. Provide coarse grout in grout spaces 2 inches or greater in all horizontal dimensions provided the clearance between reinforcing and masonry is not less than 3/4 inch.
3.4 MORTAR JOINTS: Uniform thickness of 3/8 inch unless otherwise indicated. Tool exposed joints slightly concave with a round or other suitable jointer when the mortar is thumb print hard. For horizontal joints, jointers shall be at least 12 inches long for brickwork and 16 inches long for concrete masonry. Jointers shall be slightly larger than the width of the joint so that complete contact is made along the edges of the units, compressing and sealing the surface of the joint. Strike flush joints that will not be exposed. Tool vertical joints first. Brush joints to remove all loose and excess mortar. Horizontal joints shall be level; vertical joints shall be plumb and in alignment from top to bottom of wall within a tolerance of plus or minus 1/2 inch in 40 feet.
3.5 TOLERANCES: Masonry work shall be within the following limits:
a. Pilasters and Columns: 1/4 inch from true line.
b. Face of Brick: 1/32 inch from face of adjacent brick.
c. Face of Concrete Masonry Unit: 1/16 inch from face of adjacent unit.
d. Variation From True Plane: 1/4 inch in 10 feet and 1/2 inch maximum in 20 feet or more.
e. Variation From Plumb: 1/4 inch in each story, noncumulative and 1/2 inch maximum in two stories or more.
f. Variation From Level: 1/8 inch in 3 feet, 1/4 inch in 10 feet, and 1/2-inch maximum.
g. Variation in Wall Thickness: Plus or minus 1/4 inch.
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3.6 BRICKWORK: Provide brickwork that conforms to requirements of paragraph entitled "Tolerances" of this Section. Select and place brick so that better face of stretchers and headers are exposed.
a. Testing: Except during cold weather, as defined under Environmental Conditions, test clay or shale brick daily on the job, prior to laying, as follows: Using a wax pencil, draw a circle the size of a quarter on five randomly selected bricks. Apply 20 drops of water with a medicine dropper to the surface within the circle on each brick. If the average time that the water is completely absorbed in the five bricks is less than 1-1/2 minutes, wet bricks represented by the five bricks tested. Ensure that each brick is nearly saturated 24 hours prior to placement and surface dry when laid. During cold weather, brick units that require wetting shall be sprinkled with warm or hot water just before laying.
b. Application: Unless indicated or specified otherwise, lay brick in running bond. Fill joints between bricks completely with mortar. Form bed joints of a thick layer of mortar slightly furrowed. Form head joints by applying a full coat of mortar on the brick to be laid. The practice of slushing head joints will not be permitted. Lay closure bricks with mortar on all bedding surfaces of unit to be laid and units in place. Place the brick carefully without disturbing the brick previously laid. Dry or butt joints will not be permitted.
c. Brick-Faced Walls: Bond the two wythes in every sixth brick course with continuous horizontal joint reinforcement. Provide additional bonding ties spaced not more than 3 feet apart around the perimeter of and within 12 inches of all openings.
(1) Collar Joints: Fill collar joints solid with mortar as each course of brick is laid. Do not disturb units in place.
(2) Brick Sills: Lay brick on edge, slope, and project not less than 1/2 inch beyond the face of the wall to form a wash and drip. Fill all joints solidly with mortar and tool.
d. Cavity Walls: Provide a continuous cavity as indicated. Securely tie the two wythes together with horizontal joint reinforcement. Bevel mortar beds away from cavity to prevent projection into cavity when bricks are shoved in place. Keep cavities clear and clean of mortar droppings. Provide weep holes of open head joints spaced 24 inches o.c. wherever the cavity is interrupted.
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3.7 CONCRETE MASONRY UNIT WORK: Lay the first course in a full bed of mortar for the full width of the unit. Lay succeeding courses in running bond unless otherwise indicated. Form bed-joints by applying the mortar to the entire top surfaces of the inner and outer face shells. Form head joints by applying the mortar for a width of about 1 inch to the ends of the adjoining units. The mortar shall be of such thickness that it will be forced out of the joints as the units are placed in position. Where anchors, bolts, and ties occur within the cells of the units, place metal lath in the joint at the bottom of such cells, and fill the cells with mortar or grout as the work progresses. Use solid block for bonding walls, working out the coursing, topping out walls under sloping slabs, distributing concentrated loads, backing brick headers, and elsewhere as required. No wetting of concrete masonry units is permitted.
a. Special Concrete Masonry Unit Work: Select units for uniformity of size, texture, true plane, and undamaged edges and ends of exposed surfaces. Place units plumb, parallel, and with properly tooled joints of maximum 3/8-inch thickness. Keep exposed surfaces clean and free from blemishes or defects. Lay units in the bond pattern indicated.
b. Reinforced Concrete Masonry Unit Walls: Where vertical reinforcement occurs, fill cores solid with grout. Lay units in such a manner as to preserve the unobstructed vertical continuity of cores to be filled. The cells to be grouted must be fully bedded in mortar, including the webs to prevent leakage. Remove mortar fins protruding from joints before grout is placed. Minimum clear dimensions of vertical cores shall be 2 by 3 inches. Position reinforcing accurately as indicated before placing grout. As masonry work progresses, secure vertical reinforcing in place at vertical intervals not to exceed 160 bar diameters. Grouting shall be performed as soon as possible after placing units so shrinkage cracking at the joints is minimized and so the grout bonds with the mortar. Use puddling rod or vibrator to consolidate the grout. Minimum clear distance between masonry and vertical reinforcement shall be not less than 1/2 inch. Unless indicated or specified otherwise, form splices by lapping bars not less than 40 bar diameters and wire tying them together.
3.8 BONDING AND ANCHORING: Unless indicated otherwise, extend partitions from the floor to the bottom of the construction above. Structurally bond or anchor walls and partitions to each other and to concrete walls, beams, and columns. Securely anchor non-load-bearing partitions and interior walls to the construction above in a manner that provides lateral stability while permitting unrestricted deflection of construction above. Completely embed anchors in mortar joints. Partial height partitions, less than height of ceiling, should be capped with solid (not filled) masonry units.
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a. Corners of Load-Bearing Walls: Provide a true masonry bond in each course, except where indicated or specified otherwise.
b. Intersections of Load-Bearing Walls: Provide a true masonry bond in each course, or anchor with rigid steel anchors not more than 2 feet apart vertically, unless otherwise indicated.
c. Intersections of Non-Load-Bearing Partitions With Other Walls or Partitions: Tie with wire mesh ties at vertical intervals of not more than 2 feet or with masonry bonding in alternate courses, unless otherwise indicated.
d. Masonry Walls Facing or Abutting Concrete Members: Anchor masonry to the concrete with dovetail or wire-type anchors inserted in slots or inserts built into the concrete, unless otherwise indicated. Locate anchors not more than 18 inches o.c. vertically and not more than 24 inches o.c. horizontally.
e. Brick Veneer on Wood Frame: Provide corrugated metal ties nailed to wood studs at 16 inches o.c. both ways.
3.9 THROUGH-WALL FLASHING: Provide at 2 feet o.c. Unless indicated otherwise, extend flashing from a point 1/4-inch outside of the exterior face of walls, upward across wall cavity. Bend down the exterior edge to form a drip. Flashing shall be terminated 3/4-inch back from interior face of walls and turned back on itself not less than 1/2-inch. Secure flashing in reglets to ensure a permanent watertight joint. Provide flashing in lengths as long as practicable. Lap ends not less than 1-1/2 inches for interlocking type and 4 inches for other types. Seal laps as necessary to ensure watertight construction. Provide dams at ends of flashing where masonry abuts concrete and where flashing ends within the masonry.
3.10 WEEP HOLES: Wherever through-wall flashing occurs, provide weep holes to drain the flashing to the exterior. Weep holes shall be open head joints 24 inches o.c., clear round holes not less than 1/4 inch in diameter and 24 inches o.c., or 1/4-inch diameter wicking 16 inches o.c. Wicking shall extend from the exterior face of the masonry to and approximately 2 inches upward into the cavity or collar joint.
3.11 HORIZONTAL JOINT REINFORCEMENT: Provide reinforcement in first bed joint above foundation walls or grade beams, in first and second bed joints above and below openings and extending 24 inches beyond openings each side in walls and partitions of concrete masonry units. Provide additional reinforcement in every other course. Provide in every course of concrete masonry unit walls of elevator shafts. Reinforcement shall be continuous except at
6.19 04200-14 394.107.001 SECTION 04200
UNIT MASONRY
control joints and expansion joints. Reinforcement above and below openings shall extend not less than 24 inches beyond each side of openings. Provide reinforcement in the longest available lengths, utilizing the minimum number of splices. Overlap ends not less than 6 inches. Provide welded L-shaped assemblies and welded T-shaped assemblies to match the straight reinforcement, at corners and intersections of walls and partitions. Provide mortar cover for the wire of at least 5/8 inch for exterior face of wall and 1/2 inch for interior face of wall.
3.12 CONCRETE MASONRY UNIT LINTELS AND BOND BEAMS: Provide special units, fill cells solidly with grout, and provide not less than two No. 5 reinforcing bars, unless indicated otherwise. Reinforcing shall overlap a minimum of 40 bar diameters at splices. Terminate bond beams and reinforcing on each side of expansion joints and control joints. Concrete masonry units used for lintels and bond beams shall have exposed surfaces of the same material and texture as the adjoining masonry units. Lintels shall be straight and true and shall have at least 8 inches of bearing at each end. Cells under lintel bearing on each side of openings shall be filled solid with grout or concrete for 2courses. Allow lintels to set at least 6 days before shoring is removed. During mixing, add water-repellant admixture in quantity recommended by the admixture manufacturer to concrete and grout which will be used to fill lintels and bond beams in exterior walls.
3.13 CONTROL JOINTS: Provide where indicated in concrete masonry-unit walls. Provide sawed type or built-in type as required. Joints shall occur directly opposite each other on both faces of the wall and shall be filled with sealant as specified in Section 07920, "Sealants", or as indicated.
3.14 EXPANSION JOINTS: Provide where indicated in brick walls. Fill joints with a permanently flexible preformed filler material and a sealant as specified in Section 07920, "Sealants".
3.15 GROUT PLACEMENT:
3.15.1 Grouting is required at voids where reinforcing is provided and in below grade foundation walls. Refer to drawings for locations.
3.15.2 Place grout from the interior side of walls, except as approved otherwise. Protect sills, ledges, offsets, and other surfaces from grout droppings. Remove grout from such surfaces immediately. Grout shall be well mixed to prevent segregation and shall be sufficiently fluid to flow into joints and around reinforcing without leaving voids. Place grout by pumping or pouring from buckets equipped with spouts in lifts not exceeding 4 feet. Waiting time before subsequent pours of grout shall be thirty (30) to sixty (60) minutes, to prevent rupture of the
6.19 04200-15 394.107.001 SECTION 04200
UNIT MASONRY
masonry due to hydraulic pressure on the lower mortar joints and/or concrete blocks and to allow for settlement, shrinkage and absorption of excess water by the units. Keep pours at 1-1/2 inches below the top of masonry units in top course, except at the finish course. Puddle or agitate grout thoroughly to eliminate voids. Remove masonry displaced by grouting operation and re-lay in alignment with fresh mortar.
3.16 FORMS AND SHORING: Construct to the shape, lines, and dimensions of members indicated and make sufficiently rigid to prevent deflections which may result in cracking or other damage to supported masonry. Do not remove until members have cured.
3.17 PARGING: Parge the outside of masonry basement walls in contact with the earth with two coats of Type M mortar, each 3/8-inch thick. Cross-scratch the first coat and allow to cure at least 24 hours. Trowel smooth the second coat, bevel at top, and cove out to edge of footing. Extend parging not more than 4 inches above grade, unless indicated otherwise, and keep damp for at least 3 days.
3.18 CLEANING:
3.18.1 Protection: Protect work which may be damaged, stained, or discolored during cleaning operations.
3.18.2 Pointing: Upon completion of masonry work and before cleaning, cut out defective mortar joints and tuck point joints and all holes solidly with prehydrated mortar.
3.18.3 Cleaning: Clean exposed masonry surfaces with clear water and stiff fiber brushes and rinse with clear water. Where stains, mortar, or other soil remain, continue scrubbing with warm water and detergent. Immediately after cleaning each area, rinse thoroughly with clear water. Restore damaged, stained, and discolored work to original condition or provide new work.
PART 4 - MEASUREMENT & PAYMENT:
4.1 MEASUREMENT - UNIT MASONRY:
4.1.1 Measurement for Unit Masonry shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
6.19 04200-16 394.107.001 SECTION 04200
UNIT MASONRY
4.2 PAYMENT - UNIT MASONRY:
4.2.1 For Unit Masonry, not included in other unit or lump sum price items, payment for Unit Masonry will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 04200-17 394.107.001 SECTION 05120
STRUCTURAL STEEL
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall provide all labor, materials and equipment required to furnish, fabricate, deliver and erect Structural Steel as shown on the Plans, as specified, and/or directed.
1.1.2 Included are lintels, angles, anchor bolts for column bases, bearing plates, columns, beams, girders, bracing, clips, hangers and other framing.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American Association of State Highway and Transportation Officials (AASHTO) Publication:
Standard Specifications for Highway Bridges
1.2.2 American Institute of Steel Construction (AISC) Publications:
Manual of Steel Construction
Manual of Steel Construction - Load and Resistance Factor Design
Detailing for Steel Construction
Engineering for Steel Construction
1.2.3 American National Standards Institute (ANSI) Publication:
B46.1 Surface Texture (Surface Roughness, Waviness and Lay)
1.2.4 American Railway Engineering Association (AREA) Publication:
Manual for Railway Engineering (Fixed Properties)
6.19 05120-1 394.107.001 SECTION 05120
STRUCTURAL STEEL
1.2.5 American Society for Testing and Materials (ASTM) Publications:
A36/A36M Structural Steel
A53 Steel Pipe, Hot-Dipped, Zinc-Coated Welded and Seamless
A108 Steel Bars, Carbon, Cold-Finished, Standard Quality
A123 Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products
A153 Zinc Coating (Hot-Dip) on Iron and Steel Hardware
A242/A242M High-Strength Low-Alloy Structural Steel
A307 Carbon Steel Externally Threaded Standard Fasteners
A325 High-Strength Bolts for Structural Steel Joints
A449 Quenched and Tempered Steel Bolts and Studs
A490 Quenched and Tempered Alloy Steel Bolts for Structural Steel Joints
A500 Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes
A501 Hot-Formed Welded and Seamless Carbon Steel Structural Tubing
A514/A514M High-Yield-Strength, Quenched and Tempered Alloy Steel Plate, Suitable for Welding
ASTM A529/A529M Structural Steel with 42 ksi Minimum Yield Point (1/2-Inch Maximum Thickness)
A563 Carbon and Alloy Steel Nuts
6.19 05120-2 394.107.001 SECTION 05120
STRUCTURAL STEEL
A568/A568M General Requirements for Steel, Carbon and High Strength Low-Alloy Hot-Rolled Sheet and Cold-Rolled Sheet
A572/A572 High-Strength Low-Alloy Columbium-Vanadium Steels of Structural Quality
A588/A588M High-Strength Low-Alloy Structural Steel With 50 ksi (345 MPa) Minimum Yield Point to 4 in. (100 mm) Thick
A618 Hot-Formed Welded and Seamless High-Strength Low-Alloy Structural Tubing
A668 Steel Forgings, Carbon and Alloy, for General Industrial Use
A780 Repair of Damaged Hot-Dip Galvanized Coatings
A992/A992M High Strength Low-Alloy Structural Steel With 50 ksi (345 MPa) Minimum Yield Point
B695 Coatings of Zinc Mechanically Deposited on Iron and Steel
C827 Standard Test Method for Change in Height at Early Ages of Cylindrical Specimens from Cementitious Mixtures
F436 Hardened Steel Washers
F844 Washers, Steel, Plain (Flat), Unhardened for General Use
F959 Compressible-Washer-Type Direct Tension Indicators for Use With Structural Fasteners
1.2.6 American Welding Society, Inc. (AWS) Publication:
D1.1 Structural Welding Code - Steel
1.2.7 Crane Manufacturers Association of America (CMAA) Specification:
70 Electric Overhead Traveling Cranes
6.19 05120-3 394.107.001 SECTION 05120
STRUCTURAL STEEL
74 Top Running and Under Running Single Girder Electric Overhead Traveling Cranes Utilizing Under Running Trolley Hoist
1.2.8 Steel Structures Painting Council (SSPC) Publications:
PA 1 Shop, Field, and Maintenance Painting
Paint 25 Red Iron Oxide, Zinc Oxide, Raw Linseed Oil and Alkyd Primer
SP 2 Hand Tool Cleaning
SP 3 Power Tool Cleaning
SP 6 Commercial Blast Cleaning
1.3 SYSTEM DESCRIPTION: Provide the structural steel system, including shop primer, complete and ready for use. Structural steel systems including design, materials, installation, workmanship, fabrication, assembly, erection, inspection, and testing shall be provided in accordance with AISC "Manual of Steel Construction", and/or "Manual of Steel Construction - Load and Resistance Factor Design", except as modified in this Section.
1.4 MODIFICATIONS TO REFERENCES: The "Specification for the Design, Fabrication, and Erection of Structural Steel for Buildings", including Supplement No. 1; the "Code of Standard Practice for Steel Buildings and Bridges", and "Structural Joints Using ASTM A325 or A490 Bolts" except as modified in this Section, shall be considered a part of the AISC "Manual of Steel Construction" and is referred to in this Section as the AISC "Manual of Steel Construction". The "Load and Resistance Factor Design Specification for Structural Steel Buildings", the "Code of Standard Practice for Steel Buildings and Bridges", the "Load and Resistance Factor Design Specifications for Structural Joints Using ASTM A325 or A490 Bolts", and the "Allowable Stress Design Specification for Structural Joints Using ASTM A325 or A490 Bolts" including Appendix A shall be considered a part of the AISC "Manual of Steel Construction - Load and Resistance Factor Design" and is referred to in this Section as the AISC "Manual of Steel Construction - Load and Resistance Factor Design".
6.19 05120-4 394.107.001 SECTION 05120
STRUCTURAL STEEL
1.5 SUBMITTALS:
1.5.1 Shop Drawings: Submit for approval prior to fabrication. Prepare in accordance with AISC "Detailing for Steel Construction" and AISC "Engineering for Steel Construction". Shop drawings shall not be reproductions of Contract Drawings. Include complete information for the fabrication and erection of the structure's components, including the location, type, and size of bolts, welds, member sizes and lengths, connection details, blocks, copes, and cuts. Use AWS standard welding symbols. Shoring and temporary bracing shall be designed and sealed by a registered professional engineer and submitted with calculations, as part of the shop drawings. Review of shop drawings shall be for size and arrangement of principal and auxiliary members and strength of connections. Dimensions and proper fit shall be the responsibility of the Contractor.
1.5.2 Erection Plan: Submit for record purposes. Indicate the sequence of erection, temporary shoring and bracing, and a detailed sequence of welding, including each welding procedure required.
1.5.3 Manufacturer's Data: Submit for the following:
a. Shop primer, including test report for Class B primer.
1.5.4 Certificates of Compliance: Submit for the following:
a. Steel
b. Bolts, nuts, and washers
c. Shop primer
d. Welding electrodes and rods
e. Nonshrink grout
1.5.5 Field Survey: Submit written field survey results for overhead, top running crane rail beam verifying tolerance requirements, area out of tolerance and proposed corrective measures.
6.19 05120-5 394.107.001 SECTION 05120
STRUCTURAL STEEL
1.5.6 Welder's, Welding Operator's, and Tacker's Qualifications: Prior to welding, submit certification for each stating the type of welding and positions qualified for, the code and procedure qualified under, date qualified, and the firm and individual certifying the qualification tests.
PART 2 - PRODUCTS
2.1 STEEL:
2.1.1 Structural Steel: ASTM A36.
2.1.2 High-Strength Low-Alloy Structural Steel: ASTM A572, Grade 50.
2.1.3 Structural Steel Tubing: ASTM A500, Grade B;
2.1.4 Steel Pipe: ASTM A53, Type E or S, Grade B, weight class STD (Standard); ASTM A501.
2.1.5 Sag Rods: ASTM A36.
2.2 BOLTS, NUTS, AND WASHERS: Provide the following unless indicated otherwise.
2.2.1 Structural Steel Joints:
2.2.1.1 Bolts: ASTM A325, Type 1; ASTM A490, Type 1 or 2.
2.2.1.2 Nuts: ASTM A563, Grade C and heavy hex style or as specified in the applicable ASTM bolt standard.
2.2.1.3 Washers: ASTM F436, plain carbon steel.
2.2.2 Foundation Anchorage:
2.2.2.1 Bolts: ASTM F1554, Grade A36.
2.2.2.2 Nuts: ASTM A563, Grade C, heavy hex style, except nuts under 1.5 inches may be provided in hex style.
6.19 05120-6 394.107.001 SECTION 05120
STRUCTURAL STEEL
2.2.2.3 Washers: ASTM F844.
2.3 STRUCTURAL STEEL ACCESSORIES:
2.3.1 Welding Electrodes and Rods: AWS D1.1. Welding rods for manual shielded metal arc-welding shall conform to E-70 series of ASTM A233.
2.3.2 Nonshrink Grout: Grout shall be nonmetallic such as "Embeco" as manufactured by Master Builders, "Introplast" as manufactured by Sika, or equal.
2.3.3 Welded Shear Stud Connectors: AWS D1.1 and ASTM A108.
2.4 SHOP PRIMER: SSPC Paint 25, except provide a Class B coating in accordance with AISC "Manual of Steel Construction" for slip critical joints.
2.5 OVERHEAD, TOP RUNNING CRANE RAIL: AREA "Manual for Railway Engineering", 1000 pound crane rail section and welded joints. Provide rail fasteners and a minimum rail length of 10 feet.
2.6 FABRICATION:
2.6.1 Markings: Prior to erection, members shall be identified by a painted erection mark. Connecting parts assembled in the shop for reaming holes in field connections shall be match marked with scratch and notch marks. Do not locate erection markings on areas to be welded. Do not locate match markings in areas that will decrease member strength or cause stress concentrations. Manufacturer's symbol and grade markings shall appear on all bolts and nuts.
2.6.2 Shop Primer: Shop prime structural steel, except as modified herein, in accordance with SSPC-PA 1. Do not prime steel surfaces embedded in concrete, galvanized surfaces, surfaces designed as part of a composite steel concrete section, or surfaces within 0.5 inch of the toe of the welds prior to welding (except surfaces on which metal decking is to be welded). Slip critical surfaces shall be primed with a Class B coating. Prior to assembly, prime surfaces which will be concealed or inaccessible after assembly. Do not apply primer in foggy or rainy weather; when the ambient temperature is below 45 degrees F or over 95 degrees F; or when the primer may be exposed to temperatures below 40 degrees F within 48 hours after application, unless approved otherwise by the Engineer.
6.19 05120-7 394.107.001 SECTION 05120
STRUCTURAL STEEL
2.6.2.1 Cleaning: SSPC SP 2 or 3, except that exposed exterior steel surfaces shall be cleaned in accordance with SSPC SP 6. Maintain steel surfaces free from rust, dirt, oil, grease, and other contaminants through final assembly.
2.6.2.2 Primer: Apply primer to a minimum dry film thickness of 2.0 mil except provide the Class B coating for slip critical joints in accordance with the coating manufacturer's recommendations. After erection, repair damaged primed surfaces with an additional coat of primer.
2.6.3 Surface Finishes: ANSI B46.1 maximum surface roughness of 125 for pin, pinholes, and sliding bearings, unless indicated otherwise.
2.6.4 Gas cutting may be used for concealed or minor items of work, i.e.: blocking, etc., but will not be allowed for cutting or enlarging of bolt holes. Bearing ends of columns shall be accurately milled to a plane surface perpendicular to the axis of the shaft.
2.6.5 Provide holes required for use of other trades that can be determined prior to fabrication of structural steel.
PART 3 - EXECUTION
3.1 INSTALLATION:
3.1.1 Overhead, Top Running Cranes: Runway rails and beams shall be provided in accordance with AISC "Manual of Steel Construction - Load and Resistance Factor Design" and CMAA 70, except that in case of conflict, the requirements of CMAA 70 shall govern. In addition, provide a maximum vertical difference of 0.03 inch in the elevation between adjacent runway rail tops and adjacent runway beam tops at joints. Provide adjustable runway support connections to allow placement of the crane rails and beams to the tolerances specified. Stagger runway rail joints a minimum of one foot, except that the stagger shall not be the same as the crane wheel spacing.
3.2 ERECTION:
3.2.1 Column baseplates and leveling plates shall be set level to correct elevations and temporarily supported on steel wedges or shims until the supported members have been plumbed and grouted.
6.19 05120-8 394.107.001 SECTION 05120
STRUCTURAL STEEL
3.2.2 After final positioning of steel members, provide full bearing under baseplates and bearing plates using nonshrink grout. Place nonshrink grout in accordance with the manufacturer's instructions. The entire bearing area under the plates shall be grouted solid.
3.2.3 Templates shall be furnished as required for the accurate placement of anchor bolts and bearing plates.
3.2.4 Structural steel framing shall be carried up true and plumb, and temporary bracing shall be used wherever necessary to withstand all loads to which the structure may be subjected, including erection equipment and its operation. Bracing shall be left in place as long as may be required for safety and then removed by the Contractor. As erection progresses, the work shall be securely connected to take care of all dead load, wind and erection stresses.
3.3 CONNECTIONS: Except as modified in this Section, connections not detailed shall be designed in accordance with "Manual of Steel Construction - Load and Resistance Factor Design". Build connections into existing work. Shop connections shall be welded. All connections shall be properly designed for the moments or shears shown on the drawing, or for the standard end loads of the members to be connected as tabulated for uniform loads in the AISC Handbook. Provide for unusual end loads where necessary. All welding shall be performed with procedures and by operators recently certified in accordance with the standards of the American Welding Society. Connections shall be types shown on the drawings and/or specified. No burning of holes for connections will be allowed. Field holes shall be drilled. Punch, sub-punch and ream, or drill bolt holes. Bolts, nuts, and washers shall be clean of dirt and rust, and lubricated immediately prior to installation.
3.3.1 Tightening of Shear/Bearing Connections: ASTM A307 and ASTM A325N bolts, in connections not defined as slip critical or subject to direct tension loads, shall be tightened to a "snug tight" fit. "Snug tight" is the tightness that exists when plies in a joint are in firm contact. If firm contact of joint plies cannot be obtained with a few impacts of an impact wrench, or the full effort of a worker using a spud wrench, contact the Engineer for further instructions. Bolts which may be tightened only to a snug tight condition shall be clearly identified on the drawing.
3.3.2 Tightening of Connections Requiring Full Pretensioning: ASTM A325 and A490 bolts shall be fully tensioned to 70 percent of their minimum tensile strength. ] Bolts shall be installed in connection holes and initially brought to a snug tight fit. After the initial tightening procedure, bolts shall then be fully tensioned, progressing from the most rigid part of a connection to the free edges.
6.19 05120-9 394.107.001 SECTION 05120
STRUCTURAL STEEL
3.3.3 Tightening of Foundation Bolts: Unless otherwise directed, anchor bolts shall be set prior to concrete pouring. Do not tighten with an impact torque wrench and/or until concrete has cured minimum of 14 days.
3.4 WELDING: AWS D1.1. Grind exposed welds smooth as indicated. Provide AWS D1.1 qualified welders, welding operators, and tackers.
3.4.1 Removal of Temporary Welds, Run-Off Plates, and Backing Strips: Remove only from finished areas.
3.4.2 Field welding will not be permitted on primed or painted steel. Contractor is responsible for properly cleaning steel before welding.
3.6 FIELD QUALITY CONTROL: Perform field tests, and provide labor, equipment, and incidentals required for testing. The Engineer shall be notified in writing of defective welds within 7 working days of the date of weld inspection.
3.6.1 Welds:
3.6.1.1 Furnish the services of AWS-certified welding inspectors for fabrication, erection, testing and verification inspections. Welding inspectors shall inspect and mark welds, including fillet weld end returns. All defective welds that have been repaired shall be retested.
3.6.1.2 Shop welds required for structural connections shall be visually inspected and approved by an independent testing laboratory. All questionable welds shall be radiographically or ultrasonically tested. If questionable welds prove defective, Contractor shall test minimum 10% or all other welds at no additional cost.
3.6.1.3 Field welds required for structural connections shall be visually inspected and approved by independent testing laboratory. All questionable welds and at least 10% of all other welds shall be tested by magnetic particle testing or ultrasonic testing.
3.6.2 Bolts:
3.6.2.1 Fully Pretensioned Connections: Engineer shall require Contractor to verify bolt tension on a minimum of 10 percent of fasteners. Contractor shall provide and operate bolt tension indicator device.
6.19 05120-10 394.107.001 SECTION 05120
STRUCTURAL STEEL
3.6.3 Overhead, Top Running Crane Rails and Beams: Runway rails and beams shall be surveyed (horizontally and vertically) after installation to verify compliance with the tolerance requirements of CMAA 70 and the additional tolerance requirements specified in this Section. After each survey, submit a written report to the Engineer with the following information: field survey results, tolerance requirements, areas out of tolerance, and proposed corrective measures. Proposed corrective measures shall be approved by the Engineer. Following completion of corrective measures, areas that were previously out of tolerance shall be re-surveyed and another written report shall be furnished to the Engineer. Field surveys shall be performed and sealed by a registered land surveyor.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - STRUCTURAL STEEL:
4.1.1 Measurement for Structural Steel shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - STRUCTURAL STEEL:
4.2.1 For Structural Steel, not included in other unit or lump sum price items, payment for Structural Steel will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 05120-11 394.107.001 SECTION 05313
STEEL FLOOR DECKING
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall provide all labor, materials and equipment required to furnish and install Steel Floor Decking and accessories, as shown on the Plans, and/or as specified.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American Iron and Steel Institute (AISI) Publication:
SG671 Specification for the Design of Cold-Formed Steel Structural Members
1.2.2 American Society for Testing and Materials (ASTM) Publications:
A525 Steel Sheet, Zinc-Coated (Galvanized) by the Hot-Dip Process, General Requirements
A611 Steel, Cold-Rolled Carbon
A653 Steel Sheet, Zinc Coated (Galvanized) or Zinc-Iron Alloy- Coated (Galvannealed) by the Hot-Dip Process
1.2.3 American Welding Society, Inc. (AWS) Publications:
D1.1 Structural Welding Code - Steel
D1.3 Structural Welding Code - Sheet Steel
1.2.4 National Fire Protection Association (NFPA) Publication:
70 National Electric Code
6.19 05313-1 394.107.001 SECTION 05313
STEEL FLOOR DECKING
1.2.5 Steel Deck Institute (SDEI) Publication:
DMCDFDRD Design Manual for Composite Decks, Form Decks and Roof Decks
1.2.6 Underwriters Laboratories, Inc. (UL) Publication:
209 Cellular Metal Floor Raceway and Fittings
1.3 SUBMITTALS: Submit the following.
1.3.1 Manufacturer's Catalog Data: Submit manufacturer's catalog data for floor deck and accessories. Include decking design properties, allowable loadings, and applicable published literature covering the specific type of construction required by this project. Submit and obtain approval before delivery of material to the project site.
1.3.2 Drawings: Before starting work, submit completely detailed shop drawings indicating details of decking, accessories, connections, bearing on supports, methods of anchoring, attachment of accessories, adjusting plate details, floor layout, placement directions, structural properties including composite section properties where required, size and location of holes to be cut and reinforcement provided, type and sequence of welded connections, and other pertinent details.
1.3.3 Statements: Welder Certification: Submit qualifications of welders and duration of qualification period in accordance with AWS.
1.3.4 Certificates of Compliance:
a. Steel deck materials - Submit manufacturers certification attesting that floor decks meet the requirements of SDI and AISI.
1.4 DELIVERY AND STORAGE: Do not damage or overload decking and accessories during delivery, storage, or handling. Do not use decking for storage or as working platform until units have been welded into position. Stack decking on platforms or pallets and cover with weathertight ventilated covering. Elevate one end during storage to provide for drainage. Contractor is responsible for replacing damaged material.
6.19 05313-2 394.107.001 SECTION 05313
STEEL FLOOR DECKING
PART 2 - PRODUCTS
2.1 FABRICATION: Provide decking in accordance with SDEI DMCDFDRD. Decking shall have the structural properties indicated on drawings. Deck units shall conform to manufacturer's published load tables. Deck shall safely support uniformly distributed weight of wet concrete (as determined by slab thickness), and calculated deflection shall not exceed L/180 for maximum span.
2.2 MATERIALS: Provide products of a manufacturer that is regularly engaged in production of steel deck units and accessories.
2.2.1 Steel Floor Decks: Thickness of steel used in fabrication of decking shall not be less than 0.028 inches before galvanizing and shall meet requirements of AISI SG671, except as modified herein.
2.2.1.1 Composite Steel Floor Decking: Provide one of the following types of shear devices:
a. Mechanically-varied shear devices such as wires, resistance welded across corrugations of decks by the manufacturer. Size and spacing of wires as recommended by the manufacturer and in accordance with recognized structural design practice.
b. Mechanically-fixed shear devices such as embossments, holes, or welded buttons.
c. Mechanically-fixed shear devices such as inverted, triangular-shaped ribs.
2.2.1.2 Shop Painting: Shop paint on underside of decking shall be of a type that is suitable for field application of finish painting, as specified in Section 09900, "Painting" and or as shown.
2.2.2 Accessories:
2.2.2.1 Adjusting Plates: Use adjusting plates of the same gage and configuration as decking. Use factory-cut plates of predetermined size where possible.
2.2.2.2 End Closures: Factory fabricated of sheet metal.
2.2.2.3 Partition Closures: Factory fabricated of flexible rubber or sheet metal.
6.19 05313-3 394.107.001 SECTION 05313
STEEL FLOOR DECKING
2.2.2.4 Cover Plates: Sheet metal. Polyethylene-coated, self-adhesive, 2-inch wide joint tape may be provided in lieu of cover plates on flat-surfaced decking.
2.2.2.5 Column Flashing: Sheet metal, minimum 0.0358-inch thick or metal rib lath.
2.2.2.6 Access Hole Covers: Sheet metal, minimum 0.0474-inch thick.
2.2.2.7 Hangers: Provide clips or loops for utility systems of one or more of the following types:
a. Lip tabs or integral tabs where noncellular decking or flat plate of cellular section is 0.0474-inch thick or more, and a structural concrete fill is used over deck.
b. Slots or holes punched in decking for installation of pigtails.
c. Tabs driven from top side of decking and arranged so as not to pierce electrical cells.
d. The decking manufacturer's standard as approved by the Engineer.
PART 3 - EXECUTION
3.1 INSPECTION: Prior to installation of decking units and accessories, inspect the support structure to verify that the as-built structure will permit the indicated field installation of decking system without modification.
3.2 INSTALLATION: Install steel deck units in accordance with approved shop drawings. Place units on structural supports, properly adjusted, leveled, and aligned at right angles to supports. Report inaccuracies in alignment or leveling to the Engineer and make necessary corrections before deck units are permanently anchored. Locate end laps over supports only, with minimum lap of 2 inches. Do not use unanchored deck units as a work or storage platform. Permanently anchor all units placed by the end of each working day.
3.2.1 Anchorage Methods: After placement and alignment, and after inaccuracies have been corrected, permanently fasten steel deck units in place by welding, or with self-drilling screws or powder-actuated fasteners. Use methods as recommended by the Steel Deck Institute, subject to the Engineer's approval. Length of side and end laps of deck and intervals of fastening shall be
6.19 05313-4 394.107.001 SECTION 05313
STEEL FLOOR DECKING
as recommended by the steel deck manufacturer, but not less than 2 inches. Clamp or weight deck units to provide firm contact between deck units and structural supports while welding or fastening is being performed.
3.2.1.1 Welding: Perform welding in accordance with AWS using methods and electrodes recommended by the manufacturers of the base metal alloys being used. Welds shall be made only by operators previously qualified by test prescribed in AWS to perform the type of work required. Location, size and spacing of welds shall be in accordance with the Steel Deck Institute recommendations and as shown on the shop drawings. Clean welds immediately by chipping and wire brushing. Heavily coat welds, weld scars, cut edges, drill holes, rust spots, and damaged portions of shop finish with zinc-rich primer provided by the deck supplier and approved by the Engineer. Those welders producing unsatisfactory welding, even though they have passed qualification tests, shall be immediately recertified or replaced with qualified welders.
3.2.1.2 Fasteners: Provide powder actuated or screwed fasteners for anchoring the deck to structural supports and adjoining units. Provide positive locking-type fasteners standard with the Steel Deck Institute and the manufacturer, as approved by the Engineer.
3.2.2 Openings:
3.2.2.1 Openings required in deck larger than five square feet, or greater than 24 inches in either direction or 30 inches in diameter, shall be predetermined and provided as a part of fabrication herein.
3.2.2.2 Punching, drilling or cutting deck openings smaller than above stated for passage of pipes, ducts, or attachment of other items shall be performed in field by Contractor requiring such. Obtain approval of the Engineer for such holes or other openings larger than 6 inches in diameter.
3.2.2.3 Steel reinforcing members indicated or required around openings through decks for roof hatches, fans, and similar projections will be provided by others when shown in drawings. If not shown, but required, this Contractor shall provide such.
3.2.2.4 Steel reinforcing members required for auxiliary openings smaller than stated above and not indicated on drawings shall be provided by Contractor requiring opening.
6.19 05313-5 394.107.001 SECTION 05313
STEEL FLOOR DECKING
3.2.3 Accessories:
3.2.3.1 Adjusting Plates: Provide in locations too narrow to accommodate full-size deck units and install as shown on shop drawings.
3.2.3.2 End Closures: Provide end closure to close open ends of cells at columns, walls, and openings in deck.
3.2.3.3 Closures Above Partitions: Provide for closing voids between cells over partitions that are perpendicular to direction of cells. Provide a one-piece closure strip for partitions 4 inches nominal or less in width and two-piece closure strips for wider partitions. Provide sheet metal closures above fire-rated partitions at both sides of partition with space between filled with fiberglass insulation.
3.2.3.4 Column Flashing: Provide for spaces between floor decking and columns which penetrate the deck. Field cut flashing to fit column in the field and tack weld to decking and columns.
3.2.3.5 Access Hole Covers: Provide to seal holes cut in decking to facilitate welding of decking to structural supports.
3.2.3.6 Hangers: Provide as indicated to support utility system. Space devices so as to provide one device per 6.25 square feet.
3.3 CONCRETE WORK: Prior to placement of concrete, inspect the installed decking to ensure that there has been no permanent deflection or other damage to the decking. Decking which has been damaged or permanently deflected shall be replaced as approved by the Engineer. Concrete fill over metal deck is specified in Section 03300, "Cast-In-Place Concrete".
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - STEEL FLOOR DECKING:
4.1.1 Measurement for Steel Floor Decking shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
6.19 05313-6 394.107.001 SECTION 05313
STEEL FLOOR DECKING
4.2 PAYMENT - STEEL FLOOR DECKING:
4.2.1 For Steel Floor Decking, not included in other unit or lump sum price items, payment for Steel Floor Decking will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 05313-7 394.107.001 SECTION 05500
METAL FABRICATIONS
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall provide all labor, materials and equipment required to fabricate and erect all Metal Fabrications, complete with anchorage devices, connections, accessories and incidental work, as shown on the Plans, as specified, and/or directed.
1.1.2 No attempt is made to enumerate or describe each item of miscellaneous metal work, but simply to describe major items, certain special items, and general construction requirements for all items.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 Aluminum Association, Inc. (AA) Publications:
SAA46 Standards for Anodized Architectural Aluminum
DAF45 Designation System for Aluminum Finishes
1.2.2 American Institute of Steel Construction (AISC) Publications:
M011 Manual of Steel Construction
S326 Specifications for Structural Steel Buildings
1.2.3 American National Standards Institute, Inc. (ANSI) Publications:
SNT-101 Safety Requirements for Heavy Duty, Portable, Compressed Air Actuated Fastener Driving Tools
A14.3 Safety Requirements for Fixed Ladders
B18.2.1 Square and Hex Bolts and Screws Inch Series Including Hex Cap Screws and Lag Screws
6.19 05500-1 394.107.001 SECTION 05500
METAL FABRICATIONS
B18.2.4 Square and Hex Nuts
B18.5 Round Head Bolts
B18.21.1 Lock Washers
1.2.4 American Society for Testing and Materials (ASTM) Publications:
A36 Structural Steel
A48 Gray Iron Castings
A53 Pipe, Steel, Black and Hot-Dipped, Zinc-Coated Welded and Seamless
A123 Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products
A153 Zinc Coating (Hot-Dip) on Iron and Steel Hardware
A167 Stainless and Heat Resisting Chromium-Nickel Steel Plate, Sheet and Strip
A500 Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes
A501 Hot-Formed Welded and Seamless Carbon Steel Structural Tubing
A525 Steel Sheet, Zinc-Coated (Galvanized) by the Hot-Dip Process, General Requirements
A687 High Strength Non-Headed Steel Bolts and Studs
A786 Rolled Steel Floor Plates
B26 Aluminum-Alloy Sand Castings
6.19 05500-2 394.107.001 SECTION 05500
METAL FABRICATIONS
B108 Aluminum-Alloy Permanent Mold Castings
B209 Aluminum and Aluminum Alloy Sheet and Plate
B221 Aluminum-Alloy Extruded Bars, Rods, Wire, Shapes and Tubes
B429 Aluminum-Alloy Extruded Structural Pipe and Tube
1.2.5 American Welding Society, Inc. (AWS) Publication:
D1.1 Structural Welding Code, Steel
1.2.6 National Association of Architectural Metal Manufacturers (NAAMM) Publication:
MFM Metal Finishes Manual
1.2.7 National Fire Protection Association (NFPA) Publication:
101 Code for Safety to Life from Fire in Buildings and Structures
1.2.8 Steel Structures Painting Council (SSPC) Publications:
SP 2 Hand Tool Cleaning
SP 3 Power Tool Cleaning
SP 6 Commercial Blast Cleaning
Paint 25 Red Iron Oxide, Zinc Oxide, Raw Linseed Oil and Alkyd Primer
1.3 SUBMITTALS: Submit the following.
1.3.1 Manufacturer's Catalog Data:
a. Cover plates and frames
6.19 05500-3 394.107.001 SECTION 05500
METAL FABRICATIONS
b. Floor gratings and frames
c. Handrails
d. Safety nosings and treads
e. Steel stairs
f. Structural steel door frames
g. Trench covers and frames
1.3.2 Drawings:
a. Closure plates
b. Cover plates and frames
c. Floor gratings and frames
d. Handrails
e. Miscellaneous plates and shapes
f. Safety nosings and treads
g. Steel stairs
h. Structural steel door frames
i. Trench covers and frames
1.3.3 Certificates of Compliance: Attest that materials comply with requirements of this Specification and of referenced documents.
a. Carbon steel
b. Steel pipe and tubing
6.19 05500-4 394.107.001 SECTION 05500
METAL FABRICATIONS
c. Cast iron gratings
d. Floor plate
e. Shop primer
f. Welding electrodes and rods
g. Steel floor grating
1.3.4 Submit drawings for approval prior to fabrication. Include templates, and erection and installation details, indicating thickness, type, grade, class of metal, and dimensions. Show construction details, reinforcement, anchorage, and installation with relation to the building construction.
1.3.5 Design Calculations: Submit calculations reflecting design for equipment platforms and steel stairs. Design calculations and drawings of members (including connections) shall be prepared and sealed by a Registered New York State Professional Engineer, and submitted for approval prior to fabrication.
1.4 QUALIFICATION OF WELDERS: In accordance with AWS D1.1 using procedures, materials, and equipment of the type required for the work.
1.5 DELIVERY AND STORAGE: Protect from corrosion, deformation, and other types of damage. Store items in an enclosed area free from contact with soil and weather. Contractor shall replace and remove damaged items with new items.
PART 2 - PRODUCTS
2.1 MATERIALS: Products shall conform to the respective reference specifications and standards and to the requirements specified herein.
2.1.1 Steel and Iron: If not specified otherwise, use standard mill finished structural steel shapes or bar iron in compliance with AISC Specifications for Structural Steel Buildings.
2.1.2 Structural Carbon Steel: ASTM A36.
6.19 05500-5 394.107.001 SECTION 05500
METAL FABRICATIONS
2.1.3 Structural Tubing: ASTM A500, Grade B or ASTM A501.
2.1.4 Steel Pipe: ASTM A53, Type E or S, Grade B, standard weight unless otherwise specified.
2.1.5 Fittings for Steel Pipe: Standard malleable iron fittings.
2.1.6 Floor Plates: Steel plate where shown, shall conform to ASTM A786. Unless otherwise shown, steel plate shall be not less than 14 gauge.
2.1.7 Anchors and Fasteners: Where exposed, shall be of the same material, color, and finish as the metal to which applied.
2.1.7.1 Expansion Shields: Group, type, class, and style best suited for the purpose. Provide shields recessed not less than 2-1/2 inches into concrete or masonry, unless indicated otherwise.
2.1.7.2 Lag Screws and Bolts: ANSI B18.2.1, type and grade best suited for the purpose.
2.1.7.3 Toggle Bolts: ANSI B18.2.1 and ANSI B18.5.
2.1.7.4 Bolts, Nuts, Studs and Rivets: ANSI B18.2.4 and ASTM A687.
2.1.7.5 Powder Driven Fasteners: Use when permitted by ANSI. Follow safety provisions of ANSI SNT-101.
2.1.7.6 Lock Washers: Circular washers shall conform to ANSI B18.21.1. Beveled washers for American Standard beams and channels shall be square or rectangular, taper in thickness, and be smooth.
2.1.8 Aluminum Alloy Products: Shall conform to ASTM B209 for sheet plate, ASTM B221 for extrusions and ASTM B26 or ASTM B108 for castings, as applicable. Provide aluminum extrusions at least 1/8-inch thick and aluminum plate or sheet at least 0.050-inch thick.
2.2 DISSIMILAR MATERIALS: Where dissimilar metals are in contact, or where aluminum is in contact with concrete, mortar, masonry, wood, or absorptive materials subject to wetting, protect the surfaces with a coat of bituminous paint, or a coat of varnish or a coat of zinc chromate primer to prevent galvanic or corrosive action.
6.19 05500-6 394.107.001 SECTION 05500
METAL FABRICATIONS
PART 3 - EXECUTION
3.1 FABRICATION: By mechanics skilled in the trade and in accordance with the manufacturer's directions. Metal work shall be well formed to shape and size, with sharp lines, angles, and true curves. All work shall be fabricated to allow for expansion and contraction of materials. Provide welding and bracing of adequate strength and durability, with tight, flush joints, dressed smooth and clean.
3.2 MEASUREMENTS: Before fabrication, provide necessary field measurements and verify all measurements. Wherever possible, field measurements shall be taken prior to fabrication. Do not delay job progress; allow for trimming where final dimensions cannot be established before fabrication. The Contractor is solely responsible for fit and shall make all corrections required to items fabricated off site at no additional cost to Owner.
3.3 METAL SURFACES: Shall be clean and free from mill scale, flake rust and rust pitting; well formed and finished to shape and size, with sharp lines, angles, and smooth surfaces. Shearing and punching shall leave clean true lines and surfaces. Weld or rivet permanent connections. Welds and flush rivets shall be used and finished flush and smooth on surfaces that will be exposed after installation. Do not use screws or bolts where they can be avoided; when used, heads shall be countersunk, screwed up tight and threads nicked to prevent loosening.
3.4 CONSTRUCTION: Thickness of metal and details of assembly and supports shall give ample strength and stiffness for the minimum loads specified or indicated.
3.5 FASTENING: Provide the necessary rabbets, lugs, and brackets so that the work can be assembled in a neat and substantial manner. Holes for bolts and screws shall be drilled. Joints exposed to the weather shall be formed to exclude water. Conceal fastenings where possible.
3.6 SHOP FABRICATION: Fabrication and assembly shall be done in the shop to the greatest extent possible. Provide holes required for connection of other adjacent or adjoining work.
3.7 MISCELLANEOUS ITEMS: Provide as noted on drawing.
3.7.1 Treads and Platforms: Constructed of steel grating with abrasive nosing.
3.7.2 Railings: Provide standard weight steel pipe.
6.19 05500-7 394.107.001 SECTION 05500
METAL FABRICATIONS
3.7.3 Control-Joint Covers: Provide 2-inch wide aluminum covers, 1/4-inch thick, with beveled edges to be located on wall surfaces of concrete, masonry and tile work. Provide covers over control-joints and fasten on one side only with fasteners spaced to provide positive contact with wall surfaces on both sides of joint throughout the entire length of cover.
3.7.4 Floor Expansion Joints: Provide an assembly including galvanized steel angles anchored into the floor slabs on each side of the joint; an extruded aluminum frame fastened to the angles, with a 1/16-inch thick strip of vinyl between, and a flexible vinyl waterstop spanning across the joint; and a heavy extruded aluminum cover plate not less than 3/8-inch thick, fastened at one side with stainless steel screws, and a continuous flexible filler strip at the other edge of the cover plate.
3.7.5 Floor Gratings: Grating shall be serrated bar grating constructed of steel. Floor gratings shall be galvanized.
3.7.5.1 Design: Floor gratings to support a live load of 150 pounds per square foot for the spans indicated. The deflection shall not be greater than 0.10 inch, except that an increase of 0.03 inch will be permitted for each 6-inch increase in span length for spans greater than 2 feet.
3.7.5.2 Floor Grating: Band the ends of gratings with bars of the same or greater thickness than the metal used for grating. Weld banding in accordance with the manufacturer's standard for trim. Band diagonal or round cuts by welding bars of the same or greater thickness metal used for grating in accordance with the manufacturer's standard for trim. The tops of bearing bars, cross or intermediate bars shall be in the same plane and match the finish of the grating.
3.7.5.3 Fastening Methods: Gratings shall be anchored to structural members with clips, bolts or self drilling fasteners.
3.7.6 Handrails and Railings:
3.7.6.1 Steel Rails, Including Carbon Steel Inserts: Steel rails, including inserts in concrete, shall be steel pipe conforming to ASTM A53. Steel rails shall be 1-1/2-inch nominal size, Schedule 40. Steel railings shall be hot-dip galvanized. a. Fabrication: Jointing of posts, rail, and corners shall be by one of the following methods: (1) Flush-type rail fittings of commercial standard, welded and ground smooth with railing splice locks secured with 3/8-inch hexagonal-recessed-head setscrews.
6.19 05500-8 394.107.001 SECTION 05500
METAL FABRICATIONS
(2) Mitered and welded joints made by fitting post to top rail and intermediate rail to post, mitering corners, groove welding joints, and grinding smooth. Railing splices shall be butted and reinforced by a tight fitting interior sleeve not less than 6 inches long.
(3) Railings may be bent at corners in lieu of jointing, provided bends are made in suitable jigs and the pipe is not crushed.
b. Installation: Shall be by means of baseplates bolted to stringers or structural steel framework. Rail ends shall be secured by steel pipe flanges anchored by expansion shields and bolts, through-bolted to a backplate or by 1/4-inch lag bolts to studs or solid backing.
c. Removable Sections: Shall be as indicated.
3.7.7 Miscellaneous Plates and Shapes: ASTM A36. Provide for items that do not form a part of the structural steel framework, such as lintels, sill angles.
3.7.7.1 Built-Up Lintels: Bolt or weld together with separators if required. End bearings shall be not less than one inch per foot of span; with maximum bearing 8 inches and minimum bearing 4-1/2 inches. Set lintel with clearance of 1/2 inch above head of buck or frame.
3.7.7.2 Loose Lintels: Provide over openings in masonry walls and partitions as required to support wall loads over openings. Provide with necessary connections and fasteners or welds. Construct to have at least 8 inches bearing on masonry at each end except as otherwise indicated.
3.7.7.3 Angle Lintels: Provide masonry furring with not less than 1/4-inch by width and depth of leg 1/2 inch greater than thickness of furring. For clear spans exceeding 5 feet, support lintels by intermediate wall anchors spaced at intervals of not more than 4 feet.
3.7.8 Safety Chains and Guard Rails: Construct safety chains of galvanized wrought iron, straight link type, 3/16-inch diameter, with at least twelve links per foot, and with snap hooks on each end. Snap hooks shall be boat type and eye bolts for attachment of chains shall be galvanized 3/8-inch bolt with 3/4-inch eye diameter, anchored as indicated. Two chains, 4 inches longer than the anchorage spacing, shall be supplied for each guarded area. Locate guard rails where indicated. Mount the top chain or rail 3 feet 6 inches above the floor, and mount the lower chain or rail 2 feet above the floor.
6.19 05500-9 394.107.001 SECTION 05500
METAL FABRICATIONS
3.7.9 Safety Treads: Match grating size and type, and provide checkered plate nosing at each tread.
3.7.10 Sleeves: Fit pipes passing through concrete or masonry construction with pipe sleeves. Extend each sleeve through its respective wall and cut flush with each surface. Provide sleeves at least one inch greater in diameter than the pipe passing through them. Caulk sleeve and pipe after the piping is installed and tested. Reference Specification Section 07920, "Sealants".
3.7.11 Steel Stairs: Provide steel stairs complete with structural or formed channel stringers, grating treads, landings, columns, handrails, and necessary bolts and other fastenings. Steel stairs and accessories shall be hot-dip galvanized. Reference Specification Section 05510, “Metal Stairs”.
3.7.11.1 Design Loads: Design stairs to safely sustain a live load of not less than 100 pounds per square foot, except that stair landings shall be designed to sustain a minimum live load of 150 pounds per square foot.
3.7.11.2 Materials: Steel stairs shall be of structural steel reinforced properly and in a manner to provide rigid construction, and shall be of welded construction except that rivets or bolts may be used where welding is not practicable; screw or screw-type connections are not permitted.
a. Structural Steel: Shall conform to ASTM A36.
b. Gratings for Treads and Landings: Gratings shall have non-slip nosings.
c. Steel grating shall be supported on angle cleats welded to stringers. Stringers shall be continued around as shown, and shall have an angle welded on to support the steel landings. Exposed ends shall be closed.
3.7.11.3 Installation: Provide anchor bolts, grating fasteners, washers, and all parts or devices necessary for proper installation. Use lock washers under nuts.
3.7.12 Structural Steel Door Frames: Provide frames of rolled shapes as shown on the drawings. Provide heads mitered and welded to the jambs or have riveted clip angle connections concealed in the finished work. Frames for swinging doors shall have 5/8-inch by 1-1/2-inch solid bar stops secured to the frame by welding or 1/4-inch diameter countersunk machine screws spaced not more than 12 inches on centers. Provide for head openings greater than 3 feet with
6.19 05500-10 394.107.001 SECTION 05500
METAL FABRICATIONS
additional stiffening sufficient to limit deflection to not more than 1/16-inch. Secure frames to masonry with bent zinc-coated metal anchors spaced not more than 30 inches on centers. Where necessary to engage sufficiently the threads of machine screws for fastening hardware, back frames on inside faces with steel plates of suitable thickness; tap frames and reinforcing plates as necessary for the installation of hardware and other work. Countersink rivets and screw heads where exposed in the finished work. Grind welds smooth.
3.7.13 Trench Covers and Frames: Shall be structural steel shapes and plates, with steel straps welded to frame for anchoring to concrete. Weld all corners and frames. Frame construction so that tops of frames and cover plate will finish flush with floor. Provide cover checkered steel floor plate as specified. Provide holes for removal tools. Remove sharp edges and burrs from cover plates and exposed edges of frames. Reinforce covers with structural steel channels where clear spans exceed 24 inches. Reinforcing channels shall be 24 inches on center as required. Frames, covers, and reinforcing are hot-dip galvanized and shop painted.
3.8 ANCHORAGE, FASTENINGS, AND CONNECTIONS:
3.8.1 Anchorage: Provide anchorage for fastening work securely in place. Set anchors in concrete as the work progresses and space not more than 2 feet on centers unless indicated otherwise. Sizes, kinds, and spacings of anchors not indicated or specified shall be as necessary for the purpose, as approved. Anchorage not otherwise specified or indicated includes slotted inserts, expansion shields, and powder-driven fasteners, when approved for concrete; toggle bolts and through bolts for masonry; machine and carriage bolts for steel; through bolts, lag bolts, and screws for wood. Provide inserts of suitable and approved types where required for support or anchorage of equipment and finish construction. Inserts shall be gray or malleable iron castings or galvanized steel unless indicated or specified otherwise. Slotted inserts shall be of types required to engage with anchors. Except where specified otherwise, anchors and anchor bolts in exterior walls shall be zinc-coated, and all other anchors and anchor bolts shall be heavily coated with bituminous paint.
3.8.1.1 Fastenings: Do not use wood plugs in any material. Use nonferrous attachments for nonferrous metal. Make exposed fastenings of compatible materials, generally matching in color and finish, and harmonizing with the material to which fastenings are applied. Conceal fastenings where practicable. Drill and punch to produce clean true lines and surfaces. Countersink metal work to receive hardware.
3.8.1.2 Threaded Connections: Make threaded connections up tight so that threads are entirely concealed. Make bolted work up tight and nick the threads or bush the stem to prevent loosening. Abutting bars shall be shouldered and headed, dowelled and pinned. Pass small bars
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METAL FABRICATIONS
through larger bars and pin. Rivet, bolt, and screw heads shall be flat and countersunk in exposed work and elsewhere as required. Machine removable members and fit and secure by means of screws or bolts of proper size and approved spacing.
3.8.1.3 Anchors and Connecting Members: Provide in concrete or masonry as the work progresses, to avoid unnecessary cutting and drilling. Cut, fit, and drill as necessary so all materials are properly set in place and to permit engaging work to be properly installed.
3.8.1.4 Design Connections: Where not shown or indicated, connection details shall be in accordance with AISC M011, and connections shall be provided using A-307 or A-325 steel bolts. Provide necessary holes for securing work to building. Use lock washers under nuts.
3.8.1.5 Built-In Work: Metal work built-in with concrete or masonry shall be formed for anchorage, or be provided with suitable anchoring devices as shown or as required. Furnish metal work in ample time for securing in place as the work progresses.
3.9 WELDING: Perform welding, welding inspection, and corrective welding, in accordance with AWS D1.1. Weld in a manner to prevent permanent distortion of the connected parts. Weld continuously along the entire area of contact except where tack welding is permitted. Do not tack weld exposed connections. Grind smooth visible welds in the finished installation.
3.10 FINISHES:
3.10.1 Galvanizing: Hot-dip galvanize items specified to be zinc-coated, after fabrication where practicable. Galvanizing: ASTM A123, ASTM A153 and ASTM A525, as applicable.
3.10.1.1 Galvanize: Anchor bolts, grating fasteners, washers, and parts or devices necessary for proper installation, unless indicated otherwise.
3.10.1.2 Repair of Zinc-Coated Surfaces: Repair surfaces damaged by welding or other means with galvanizing repair paint or by the application of stick or thick paste material specifically designed for repair of galvanizing, as approved. Clean areas to be repaired, and remove the slag from the welds. Surfaces to which stick or paste material is applied, shall be heated with a torch to a temperature sufficient to melt the metallics in stick or paste; spread the molten material uniformly over surfaces to be coated and wipe the excess material off.
3.10.2 Shop Cleaning and Painting: After surface preparation, apply pretreatment and primer as specified. Do not coat surfaces of items to be embedded in concrete or to be welded. Recoat
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METAL FABRICATIONS
damaged surfaces using surface preparation, treatment, primer and paint that was applied to the adjacent surfaces upon completion of work. Do not apply bituminous protective coatings to items to be finish painted.
3.10.2.1 Environmental Conditions: Do not clean or paint surface when damp or exposed to foggy or rainy weather, when the metallic surfaces temperature is within 5 degrees F of the dew point of the surrounding air, or when the surface temperature is below 45 degrees F or over 95 degrees F, unless approved by the Engineer.
3.10.2.2 Surface Preparation: Unless otherwise specified herein, abrasive blast clean exposed surfaces in accordance with SSPC SP 6. Surfaces that will be in spaces above ceiling, attic spaces, crawl spaces, furred spaces, and chases may be cleaned in accordance with SSPC SP 2 or SP 3 in lieu of being blast cleaned. Wash cleaned surfaces which become contaminated with rust, dirt, oil, grease, or other contaminants with solvents until thoroughly clean. Steel to be embedded in concrete shall be free of dirt and grease. Do not paint or galvanize bearing surfaces, including contact surfaces within slip-critical joints, but coat them with an approved rust preventive, applied in the shop. Remove such coating just prior to field erection using a remover approved by the rust preventive manufacturer. Surfaces, when assembled, shall be free of rust, grease, dirt and other foreign matter.
3.10.2.3 Pretreatment, Priming and Painting: Apply pretreatment, primer, and paint in accordance with the manufacturer's standard practice. On surfaces concealed in the finished construction or not accessible for finish painting, apply an additional prime coat to a minimum dry film thickness of 0.1 mil. Tint the additional prime coat with a small amount of tinting pigment. Structural steel shall be shop primed with one coat SSPC Paint 25. Finish coat of paint is specified in Section 09900, "Painting".
3.10.3 Nonferrous Metal Surfaces: Protect by plating, anodic, organic, or other coatings as specified.
3.10.4 Aluminum Surfaces:
3.10.4.1 Surface Condition: Before finishes are applied, exposed aluminum sheets, plates, and extrusions shall be free of roll marks, scratches, rolled-in scratches, kinks, stains, pits, orange peel, die marks, structural streaks, and any other defects which will affect uniform appearance of finished surfaces.
6.19 05500-13 394.107.001 SECTION 05500
METAL FABRICATIONS
3.10.4.2 Aluminum: Unexposed sheet, plate and extrusions may have mill finish as fabricated. Castings shall have sandblast finish, medium, equal to NAAMM MFM, Metal Finishes Manual, Designation AA-M43 or AA SAA46, Standards for Anodized Architectural Aluminum and AA DAF45 Designation System for Aluminum Finishes of The Aluminum Association Publications.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - METAL FABRICATIONS:
4.1.1 Measurement for Metal Fabrications shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - METAL FABRICATIONS:
4.2.1 For Metal Fabrications, not included in other unit or lump sum price items, payment for Metal Fabrications will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 05500-14 394.107.001 SECTION 05510
METAL STAIRS
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section the Contractor shall furnish all labor, materials and equipment for Metal Stairs and associated reinforced concrete foundations as shown on the Plan, as specified and/or directed.
1.2 RELATED WORK SPECIFIED ELSEWHERE:
1.2.1 Reinforcing Steel: Section 03210
1.2.2 Cast-In-Place Concrete: Section 03300.
1.2.3 Metal Fabrications: Section 05500.
1.2.4 Painting: Section 09900.
1.3 REFERENCES:
1.3.1 Except as shown or specified otherwise, the work of this Section shall meet the requirements of the following:
1.3.1.1 Design, Fabrication, and Erection: “Specification for Structural Steel Buildings, Allowable Stress Design and Plastic Design” adopted by the American Institute of Steel Construction, June 1, 1989 (AISC Specification).
a. Design and Fabrication of Cold-Formed Shapes: “Specification for the Design of Cold-Formed Steel Structural Members”, by the American Iron and Steel Institute (AISI Specification).
1.3.1.2 Welding: “Structural Welding Code - Steel, AWS D1.1”, or “Structural Welding Code - Sheet Steel, AWS D1.3”, by the American Welding Society (AWS Codes).
1.3.1.3 High Strength Bolting: “Specification for Structural Joints Using ASTM A325 or A490 Bolts, August 14, 1980”, by the Engineering Foundation’s Research Council on Riveted and Bolted Structural Joints (Specification for Structural Joints).
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1.3.2 Organizations:
1.3.2.1 AISC: American Institute of Steel Construction, One East Wacker Dr., Suite 700, Chicago, IL 60601-1802, 866-275-2472, www.aisc.org.
1.3.2.2 AISI: American Iron and Steel Institute, 1140 Connecticut Ave., NW, Suite 705, Washington, D.C. 20036, (202) 452-7100, www.steel.org.
1.3.2.3 AWS: American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126, (800) 443-9353, www.aws.org.
1.3.2.4 ANSI: American National Standards Institute, 1819 L Street, NW, 6th Floor, Washington, DC 20036, (202) 293-8020, www.ansi.org.
1.3.2.5 ASME: ASME International, 3 Park Ave., New York, NY 10016-5990, (800) 843- 2763, www.asme.org.
1.3.2.6 ASTM: ASTM International, 100 Barr Harbor Dr., PO Box C700, West Conshohocken, PA, 19428-2959, (610) 832-9500, www.astm.org.
1.3.2.7 MPI: The Master Painters Institute Inc., 2808 Ingleton Ave., Burnaby, BC, V5C 6G7, (888) 674-8937, www.specifypaint.com.
1.3.2.8 SSPC: The Society for Protective Coatings, 40 24th Street, 6th Floor, Pittsburgh PA 15222-4656, (877) 281-7772, www.sspc.org.
1.4 SUBMITTALS:
1.4.1 Indicate materials, details of construction, methods of fastening, erection and foundation details. Include reference to design criteria used and stress computations. Computations and drawings must be stamped by a licensed Professional Engineer registered in New York State. Design metal stair in conformance with the latest edition of the Building Code of New York State.
1.4.2 Shop Drawings:
1.4.2.1 Include anchor bolt location plan (if any), erection drawings, and detail drawings of all components.
6.19 05510-2 394.107.001 SECTION 05510
METAL STAIRS
1.4.2.2 Indicate shop and field welds by standard AWS welding symbols in accordance with AWS A2.4.
1.4.3 Product Data:
1.4.3.1 Paint: Manufacturer’s name and printed product literature, including storage and application instructions.
1.4.3.2 Grating Treads and Platforms: Manufacturer’s specifications.
1.4.4 Quality Control Submittals:
1.4.4.1 Fabricator’s Qualifications Data: Name and experience of fabricator.
1.5 QUALITY ASSURANCE:
1.5.1 Fabricator’s Qualifications: The fabricator shall be experienced in metal stair work and shall be subject to the approval of the Engineer.
1.5.2 Inspection: Shop and field quality assurance inspection may be made by the State. If quality assurance inspection is made by the State, it shall not relieve the fabricator and erector of responsibility for their own quality control programs.
1.5.3 Galvanizing: Stamp galvanized items with galvanizer’s name, weight of coating, and applicable ASTM number.
1.6 WELDING PROCESS:
1.6.1 Use only shielded metal arc welding.
1.6.2 Shielded metal arc welding procedures that comply with the provisions of the AWS Code shall be considered to be pre-qualified.
1.7 DELAY AND STORAGE: Protect from corrosion, deformation and other types of damage. Store items in an enclosed area free from contact with soil and weather. Contractor shall replace and remove damaged items with new items.
6.19 05510-3 394.107.001 SECTION 05510
METAL STAIRS
PART 2 - PRODUCTS
2.1 MATERIALS:
2.1.1 Steel Shapes, Plates, and Bars: ASTM A36.
2.1.2 Steel Plates to be Bent or Cold-Formed: ASTM A283, Grade C.
2.1.3 Steel Bars and Bar-Size Shapes: ASTM A675, Grade 70; or ASTM A36.
2.1.4 Merchant Quality Steel Bars: ASTM A575, grade as selected by fabricator.
2.1.5 Cold-Finished Steel Bars: ASTM A108, grade as selected by fabricator.
2.1.6 Hot-Rolled Carbon Steel Sheet and Strip: ASTM A569, pickled and oiled.
2.1.7 Cold-Rolled Carbon Steel Sheet: ASTM A366, oiled.
2.1.8 Galvanized Steel Sheet: ASTM A526, with G90 hot-dip process zinc coating complying with ASTM A525.
2.1.9 Steel Tubing: Hot-formed, welded or seamless, structural tubing; ASTM A501.
2.1.10 Cold-Drawn Steel Tubing: ASTM A512, buttwelded, cold-finished carbon steel tubing, sink drawn and stress relieved.
2.1.11 Cast Iron Castings: ASTM A48, gray iron castings, Class 40.
2.1.12 Malleable Iron Castings: ASTM A47, grade as selected by fabricator.
2.1.13 Steel Castings: ASTM A27, grade and class as required by use of item.
2.1.14 Steel Pipe: ASTM A53, type as selected, Grade B; black finish unless galvanizing is required; standard weight (Schedule 40), unless otherwise shown or specified.
2.1.15 Weld Filler Metal: Weld filler metal for shielded metal arc welding which complies with AWS Specifications A5.1 or A5.5 shall be considered to be pre-qualified.
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METAL STAIRS
2.1.16 Anchors: Except where shown or specified, select anchors of type, size, style, grade, and class required for secure installation of metal fabrications. For exterior use and where built into exterior walls, anchors shall be galvanized or of corrosive-resistant materials.
2.1.16.1 Threaded-Type Concrete Inserts: Galvanized ferrous casting, internally threaded to receive 3/4 inch diameter machine bolt; either malleable iron or cast steel.
2.1.16.2 Wedge-Type Concrete Inserts: Galvanized box-type ferrous casting, designed to accept 3/4 inch diameter bolt having special wedge-shaped head; either malleable iron or cast steel.
2.1.16.3 Bolts: Carbon steel bolts having special wedge-shaped heads, nuts, washers and shims.
2.1.16.4 Slotted-Type Concrete Inserts: Galvanized 1/8 inch thick pressed steel plate complying with ASTM A 283; box-type welded construction with slot designed to receive 3/4 inch diameter square head bolt and with knockout cover.
2.1.16.5 Expansion Anchors: Anchor bolt and sleeve assembly of material indicated below with capability to sustain, without failure, a load equal to six times the load imposed when installed in unit masonry and equal to four times the load imposed when installed in concrete, as determined by testing per ASTM E 488, conducted by a qualified independent test agency.
a. Carbon Steel: Zinc-Plated; ASTM B 633, Class Fe/Zn 5. b. Stainless Steel: Bolts, Alloy Group 1 or 2; ASTM F593, Nuts; ASTM F 594.
2.1.17 Fasteners: Except where shown or specified, select fasteners of type, size, style, grade, and class required for secure installation of metal fabrications. For exterior use and where built into exterior walls, fasteners shall be galvanized.
a. Standard Bolts and Nuts: ASTM A 307, Grade A, regular hexagon head. b. Stainless Steel Fasteners: ASTM A 666; Type 302/304 for interior work; Type 316 for exterior work; Phillips flathead (countersunk) screws and bolts for exposed work unless otherwise specified. c. Eyebolts: ASTM A 489. d. Machine Bolts: ASME B18.5 or ASME B18.9, Type, Class, and Form as required. e. Machine Screws: ASME B18.6.3. f. Lag Screws: ASME B18.2.1. g. Wood Screws: Flat head, ASME B18.6.1.
6.19 05510-5 394.107.001 SECTION 05510
METAL STAIRS
h. Plain Washers: Round, ASME B18.22.1. i. Lock Washers: Helical, spring type, ASME B18.21.1. j. Toggle Bolts: Spring Wing Type; Wing AISI 1010, Trunion Nut AISI1010 or Zamac Alloy, Bolt Carbon Steel ANSI B18.6.3.
2.1.18 Bedding Mortar:
2.1.18.1 Cement Grout: One part Portland cement complying with ASTM C150, Type I or III, to 3 parts natural sand complying with ASTM C404, size No. 2, mixed with minimum amount of water required for placement and hydration. Ratio by volume.
2.1.19 Shop Paint (General): Universal shop primer; fast-curing, lead- and chromate-free, universal modified-alkyd primer complying with MPI#79 and compatible with topcoat.
2.1.19.1 Use primer containing pigments that make it easily distinguishable from zinc-rich primer.
2.1.20 Shop Paint for Galvanized Steel: Epoxy zinc-rich primer; complying with MPI#20 and compatible with topcoat.
2.1.21 Galvanizing Repair Paint: High-zinc-dust-content paint complying with SSPC-Paint 20 and compatible with paints specified to be used over it.
2.1.22 Bituminous Paint: Cold-applied asphalt emulsion complying with ASTM D 1187.
2.2 STAIR FRAMING:
2.2.1 Fabricate stringers, headers, and platform framing as shown on the drawings.
2.2.1.1 Furnish hangers, posts, and miscellaneous items as shown or required.
2.2.2 Connections: Welded or bolted as shown.
2.2.2.1 Use one-sided angle connections only where shown.
2.2.2.2 When framed connections are used, the minimum length of the connection angles shall be as follows:
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METAL STAIRS
a. Beams 12 to 14 inches deep: 8-1/2 inches. b. Beams 8 to 10 inches deep: 5-1/2 inches.
2.2.2.3 High-Strength Bolted Connections: Amend the Specification for Structural Joints as follows:
a. Refer to Item 5 (b): High-strength bolts shall have a hardened washer under the element (nut or bolt head) turned in tightening, regardless of the method of tightening. b. Refer to Item 6: The inspection of bolt tightening shall be as specified under Item 6(d).
2.2.3 Close exposed ends of stringers with continuously welded steel plates.
2.2.4 Newels: Tubular steel newels as shown on the drawings, equipped with required attachments to other work.
a. Newels shall have standard caps and bottom closures. b. Newels shall be full height of stairwell.
2.2.5 Where masonry walls support steel stair work, provide temporary supporting struts designed for erection of steel stair components before installation of masonry.
2.3 STAIR DETAILS:
2.3.1 Construct stair units to conform to sizes and arrangement indicated on the drawings. Construct stair units to support a minimum live load of 100 lb/sq ft, unless otherwise indicated.
2.3.2 Grating Treads and Platforms: Rectangular, welded steel bar grating designed to support a minimum live load of 100 lb/sq ft with deflection not exceeding 1/180. Fabricate with bearing bars on edge, and with all intersecting and abutting members joined by the electro- pressure welding method for the full depth of cross bar. Steel Bars: ASTM A569.
2.3.2 1 Fabricate grating treads with slip-resistant texture steel plate nosing on front edge and with steel angle or steel plate carrier at each end for stringer connections. Secure treads to stringers with bolts.
2.3.2.2 Fabricate grating platforms with nosing, matching that on grating treads, at edge of landings over a tread. Provide flat steel bar toeplate at open-sided edges of grating platforms.
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METAL STAIRS
2.3.2.3 Top Surface of Bearing Bars: Plain, unless otherwise indicated.
2.3.2.4 Banding: Continuous steel bar, of same material and size as bearing bars, welded to grating panel.
2.3.2.5 Finish: Grating manufacturer’s standard primer paint.
2.3.2.6 Finish: Galvanized.
2.3.3 Furring Attachment: Equip stair units with attachment clips or sub-assemblies required for anchorage of furring to stair and platform soffits where plaster/gypsum wallboard soffit is indicated on the drawings.
2.4 STAIR RAILINGS AND HANDRAILS:
2.4.1 Fabricate stair railings and handrails of 1-1/2 inch (nominal) diameter steel pipe, unless otherwise shown.
2.4.2 Railings: Unless otherwise shown, railings shall consist of top rail and intermediate rails, with posts spaced not more than 5 feet oc. Close ends of rails which do not terminate with a flange or continuous return.
2.4.2.1 Space rails as shown on drawings.
2.4.2.2 Join posts, rails, and corners by one of the following methods:
a. Flush-type steel railing fittings, welded and ground smooth, with railing splice locks secured with 3/8 inch hexagonal-recessed-head setscrews.
b. Welded joints made by fitting post to top rail and intermediate rail to post, mitering corners, groove welding joints, and grinding joints smooth. Butt railing splices and reinforce by a tight-fitting interior sleeve not less than 6 inches long.
2.4.2.3 Railings may be bent at corners instead of joining, provided the bends are uniformly formed in jigs, with cylindrical cross-section of pipe maintained throughout the entire bend.
2.4.2.4 Unless otherwise shown, fabricate railings and accessories as necessary to secure posts and rail ends to building construction as follows:
6.19 05510-8 394.107.001 SECTION 05510
METAL STAIRS
a. Anchor posts to steel with steel flanges, angle type or floor type as required by conditions, welded to posts and bolted to the steel supporting members. b. Anchor rail ends into concrete and solid masonry with round steel flanges welded to rail ends and anchored into the wall construction with lead expansion shields and bolts.
2.4.2.5 Fabricate removable railing sections as indicated on the drawings.
2.4.3 Handrails: Pipe handrails shall be secured to walls by means of wall brackets, and shall have a wall return fitting at each end of handrails unless otherwise shown.
2.4.3.1 Wall Brackets: Malleable iron castings, with not less than 3 inches projection from the finish wall surface to the center of the handrail, and with the wall plate portion of the bracket drilled to receive one 3/8 inch bolt. Brackets shall be located approximately 6 inches from each end of handrails and intermediate brackets equally spaced at intervals not exceeding 5 feet oc. Fabricate wall brackets to secure to building construction as follows:
a. Anchor into concrete and solid masonry with expansion shields and lag bolts. b. Anchor into hollow masonry and stud partitions with toggle bolts having square heads.
2.4.3.2 Wall Return Fittings: Cast iron castings, flush-type, with the same projection as specified for wall brackets.
2.4.4 Kickplates: Flat steel bars 3/16 inch thick by not less than 4 inches high. Secure kickplates.
2.5 FABRICATION:
2.5.1 Progress shop fabrication from “APPROVED” or “APPROVED AS NOTED” detail drawings only.
2.5.1.1 When detail drawings are “APPROVED AS NOTED”, progress fabrication in strict accordance with notes thereon.
2.5.1.2 Fabrication progressed from “REVISE AS NOTED - RESUBMIT” or “REJECTED – RESUBMIT AS SPECIFIED” detail drawings will be rejected. The contractor shall have no claim against the State for any costs or delays due to rejection of items fabricated from “REVISE AS NOTED - RESUBMIT” or “REJECTED – RESUBMIT AS SPECIFIED” detail drawings.
6.19 05510-9 394.107.001 SECTION 05510
METAL STAIRS
2.5.2 Use materials of the sizes and thicknesses indicated on the drawings. If not indicated, furnish items of size and thickness required to produce adequate strength and durability in the finished product for the intended use.
2.5.3 Ease exposed edges to a radius of approximately 1/32 inch unless otherwise shown. Form bent-metal corners to the smallest radius possible without causing grain separation or otherwise impairing the work.
2.5.4 Use hot-rolled steel bars for work fabricated from bar stock, unless work is indicated to be fabricated from cold-finished stock.
2.5.5 Use flush countersunk screws or bolts for exposed fasteners, unless otherwise indicated.
2.6 GALVANIZING:
2.6.1 In addition to specific items specified or noted to be galvanized, galvanize items attached to or embedded in exterior masonry (including interior wythe of exterior masonry walls) and concrete work. Galvanize all exterior items.
2.6.1.1 Unless otherwise specified or noted, items to be galvanized shall receive a zinc coating by the hot-dip process, after fabrication, complying with the following:
a. ASTM A123 for plain and fabricated material, and assembled products. b. ASTM A153 for iron and steel hardware.
2.7 SHOP PAINTING:
2.7.1 Cleaning Steel: Thoroughly clean all surfaces of metal. Remove oil, grease, and similar contaminants in accordance with SSPC SP-1 “Solvent Cleaning”. Remove loose mill scale, loose rust, weld slag and spatter, and other detrimental material in accordance with SSPC SP-2 “Hand Tool Cleaning”, SSPC SP-3 “Power Tool Cleaning”, or SSPC SP-7 “Brush-Off Blast Cleaning”.
2.7.2 Galvanized Items:
2.7.2.1 Galvanized items which are to be finish painted under Section 09900 or as shown on drawings shall be rinsed in hot alkali or in an acid solution and then in clear water.
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2.7.2.2 Welded and abraded galvanized surfaces shall be wire brushed and repaired with a coating of cold galvanizing compound.
2.7.3 Apply one coat of shop paint to all steel surfaces except as follows:
2.7.3.1 Do not shop paint steel surfaces to be field welded and contact surfaces of high- strength bolted connections.
2.7.3.2 Apply 2 coats of shop paint, before assembly, to steel surfaces inaccessible after assembly, except surfaces in contact. Also apply 2 coats of paint to surfaces which are inaccessible after erection. Change color of second coat.
2.7.3.3 Do not paint galvanized items which are not to be finish painted under Section 09900 or as shown on drawings.
2.7.4 Apply paint and compound on dry surfaces in accordance with the manufacturer’s printed instructions, and to the following minimum thickness per coat:
a. Shop Paint (General): 4.0 mils wet film. b. Shop Paint for Galvanized Steel: 3.0 mils wet film. c. Cold Galvanizing Compound: 2.0 mils dry film.
PART 3 - EXECUTION
3.1 INSTALLATION:
3.1.1 Erect metal stairs in accordance with the AISC Specification, the AWS Codes, and the Specification for Structural Joints, except as otherwise specified.
3.1.2 Install anchorage devices and fasteners where necessary for securing metal stair items to in-place construction.
3.1.3 Set the work accurately in location, alignment and elevation, plumb, level, true and free of rack, measured from established lines and levels. Provide temporary bracing and built-in anchors for items which are to be built into concrete, masonry or similar construction.
3.1.4 Check railings prior to securing in place to insure proper matching at butting joints and correct alignment throughout their length.
6.19 05510-11 394.107.001 SECTION 05510
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3.1.5 Do not make corrections or alterations to fabricated steel without prior written approval by the Director’s Representative.
3.1.6 Do not use gas or air carbon-arc cutting for cutting or enlarging bolt holes.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT – METAL STAIRS:
4.1.1 Measurement for Metal Stairs shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT – METAL STAIRS:
4.2.1 For Metal Stairs, not included in other unit or lump sum price items, payment for Metal Stairs will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 05510-12 394.107.001 SECTION 06100
ROUGH CARPENTRY
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall provide all labor, materials and equipment required to furnish and install Rough Carpentry, as shown on the Plans, as specified, and/or as directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American Institute of Timber Construction (AITC) Publication:
A190.1 Structural Glued Laminated Timber (ANSI/AITC A190.1)
1.2.2 American National Standards Institute, Inc. (ANSI) Publications:
B18.2.1 Square and Hex Bolts and Screws, Inch Series Including Hex Cap Screws and Lag Screws
B18.2.4 Square and Hex Nuts
B18.5 Round Head Bolts (Inch Series)
B18.6.1 Wood Screws (Inch Series)
1.2.3 American Plywood Association (APA) Publications:
E30-F APA Design/Construction Guide, Residential and Commercial
E445-J Performance Standards and Policies for APA Structural-Use Panels (APA PRP-108)
6.19 06100-1 394.107.001 SECTION 06100
ROUGH CARPENTRY
1.2.4 American Society for Testing and Materials (ASTM) Publications:
A525 Steel Sheet, Zinc-Coated (Galvanized) by the Hot-Dip Process, General Requirements for
A687 High-Strength Non-headed Steel Bolts and Studs
C79 Gypsum Sheathing Board
C208 Insulating Board (Cellulosic Fiber), Structural and Decorative
D2277 Fiberboard Nail-Base Sheathing
1.2.5 American Wood-Preservers' Association (AWPA) Publications:
C1 All Timber Products - Preservative Treatment by Pressure Process
C2 Standard for the Preservative Treatment of Lumber, Timber, Bridge Ties, and Mine Ties by Pressure Treatment
C9 Plywood - Preservative Treatment by Pressure Process
C28 Structural Glued Laminated Members and Laminations Before Gluing, Pressure Treatment
M2 Standard for Inspection of Treated Timber Products
M6 Brands Used on Forest Products
1.2.6 American Wood Preservers Bureau (AWPB) Publication:
LP22 Standard for Softwood Lumber, Timber, and Plywood Pressure Treated with Waterborne Preservatives for Ground Contact Use
6.19 06100-2 394.107.001 SECTION 06100
ROUGH CARPENTRY
1.2.7 Northeastern Lumber Manufacturers Association (NELMA) Publication:
SGRNL Standard Grading Rules for Northeastern Lumber
1.2.8 National Forest Products Association (NFP) Publications:
NDS National Design Specification for Wood Construction, Design Values for Wood Construction
WCD1 Manual for House Framing
1.2.9 U.S. Department of Commerce Product Standards (PS):
PS-1 Construction and Industrial Plywood
PS-2 Performance Standard for Wood-based Structural-use Panels
PS-20 American Softwood Lumber Standard
PS-56 Structural Glued Laminated Timber
PS-58 Basic Hardboard
1.2.10 Truss Plate Institute (TPI) Publications:
DSB Recommended Design Specification for Temporary Bracing of Metal Plate Connected Wood Trusses
TPI 1 National Design Standards for Metal Plate Connected Wood Truss Construction
BCSI 1 Guide to Good Practice for Handling, Installing & Bracing of Metal Plate Connected Wood Trusses
6.19 06100-3 394.107.001 SECTION 06100
ROUGH CARPENTRY
1.3 SUBMITTALS: Submit the following.
1.3.1 Design Data:
a. Modifications of structural members
Submit calculations for all proposed modifications of structural members. Do not proceed with modifications until the submittal has been approved.
1.3.2 Drawings:
a. Modifications of structural members
b. Fabricated wood trusses
Indicate materials, details of construction, methods of fastening, and erection details. Include reference to design criteria used and stress computations. Submit drawings for all proposed modifications of structural members. Do not proceed with modifications until the submittal has been approved. The design of the wood trusses shall be in accordance with the Building Code of New York State and TPI 1. Manufacture and installation of the wood trusses shall be in accordance with DSB, TPI 1 and BCSI 1. All drawings shall be signed and sealed by a Professional Engineer licensed to practice in the State of New York.
1.3.3 Statements:
a. Certificates of grade
Submit certificates attesting that products meet the grade requirements specified in lieu of grade markings where appearance is important and grade marks will deface material.
1.3.4 Factory Test Report:
a. Treatment standard compliance
Submit report required in paragraph entitled "Preservative-Treated Lumber and Plywood".
1.4 DELIVERY AND STORAGE: Deliver materials to the site in an undamaged condition. Carefully store materials off the ground to provide proper ventilation, drainage, and protection against dampness. Remove defective and damaged materials and provide new materials.
6.19 06100-4 394.107.001 SECTION 06100
ROUGH CARPENTRY
1.5 GRADING AND MARKING:
1.5.1 Lumber: Mark each piece of framing and board lumber or each bundle of small pieces of lumber with the grade mark of a recognized association or independent inspection agency. Such association or agency shall be certified by the Board of Review, American Lumber Standards Committee, to grade the species used.
1.5.2 Structural Glued Laminated Timber: Mark each member with the mark of a recognized association or independent inspection agency that maintains continuing control over the quality of structural glued laminated timber products. The marking shall indicate compliance with AITC A190.1 and shall include all identification information required by AITC A190.1.
1.5.3 Plywood: Mark each sheet with the mark of a recognized association or independent inspection agency that maintains continuing control over the quality of the plywood. The mark shall identify the plywood by species group or span rating, exposure durability classification, grade, and compliance with PS-1.
1.5.4 Structural-Use Panels: Mark each panel with the mark of a recognized association or independent inspection agency that maintains continuing control over the quality of the panel. The mark shall indicate end use, span rating, and exposure durability classification.
1.5.5 Preservative-Treated Lumber and Plywood: The Contractor shall be responsible for the quality of treated wood products. Each treated piece shall be inspected in accordance with AWPA M2 and permanently marked or branded, by the producer, in accordance with AWPA M6. The Contractor shall provide the Engineer with the inspection report of an independent inspection agency that offered products comply with applicable AWPA Standards. The AWPB LP22 Quality Mark "LP-22"on each piece will be accepted, in lieu of inspection reports, as evidence of compliance with applicable AWPA treatment standards.
1.5.6 Hardboard, Gypsum Board, and Fiberboard: Mark each sheet or bundle to identify the standard under which the material is produced and the producer.
1.6 SIZES AND SURFACING: PS-20 for dressed sizes of yard and structural lumber. Lumber shall be surfaced four sides. Size references, unless otherwise specified, are nominal sizes, and actual sizes shall be within manufacturing tolerances allowed by the standard under which the product is produced.
6.19 06100-5 394.107.001 SECTION 06100
ROUGH CARPENTRY
1.7 MOISTURE CONTENT: Air-dry or kiln-dry lumber. Kiln-dry treated lumber after treatment. Maximum moisture content of wood products shall be as follows at the time of delivery to the job site:
a. Framing lumber and boards - 19 percent maximum b. Timbers 5 inches and thicker - 25 percent maximum c. Materials other than lumber - Moisture content shall be in accordance with standard under which the product is produced
1.8 PRESERVATIVE TREATMENT: Lumber and timber shall be treated in accordance with AWPA C1 and AWPA C2, and plywood in accordance with AWPA C1 and AWPA C9. Structural glued laminated timber shall be treated in accordance with AWPA C1 and AWPA C28. All wood shall be air or kiln dried after treatment. Specific treatments shall be verified by the report of an approved independent inspection agency, or the AWPB Quality Mark on each piece. Do not incise surfaces of lumber that will be exposed. Brush coat areas that are cut or drilled after treatment with either the same preservative used in the treatment or with a 2 percent copper naphthenate solution in accordance with CCA-4, retention assay of 0.40 pounds per cubic foot. The following items shall be preservative treated:
a. Wood-framing, woodwork, and plywood up to and including the subflooring at the first-floor level of structures having crawl spaces when the bottoms of such items are 24 inches or less from the earth underneath.
b. Exterior wood steps, platforms, and railings; and all wood framing of open, roofed structures.
c. Wood sills, soles, plates, furring, and sleepers that are less than 24 inches from the ground, furring and nailers that are set into or in contact with concrete or masonry.
d. Nailers, edge strips, crickets, curbs, and cants for roof decks.
PART 2 - PRODUCTS
2.1 LUMBER:
2.1.1 Structural Lumber: Except where a specific grade is indicated or specified, Any of the species and grades listed in NFP NDS that have allowable unit stresses in pounds per square inch
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ROUGH CARPENTRY
(psi) not less than 1,200 Fb, with 1,200,000 E allowable unit stresses indicated. Use for joists, rafters, headers, trusses, beams (except collar beams), columns, posts, stair stringers, girders, and all other members indicated to be stress rated.
2.1.2 Framing Lumber: Framing lumber such as studs, plates, caps, collar beams, cant strips, bucks, sleepers, nailing strips, and nailers and board lumber such as subflooring and wall and roof sheathing shall be one of the species listed in the table below. Minimum grade of species shall be as listed.
Table of Grades for Framing and Board Lumber
Grading Rules Species Framing Board Lumber
NELMA SGRNL Balsam Fir, Eastern All Species: All Species: No. 3 Standard Grading Hemlock - Tamarack, Standard Light Common Except Rules Eastern Spruce, Framing or No. 3 Standard for Eastern Eastern White Pine, Structural Light White and Northern Northern Pine, Framing (Stud Grade Pine Northern Pine Cedar For 2 x 4 Size, 10 Feet and Shorter)
2.2 PLYWOOD AND STRUCTURAL-USE PANELS: PS-1 and APA E445-J, respectively.
2.2.1 Roof Sheathing:
2.2.1.1 Plywood: C-D Grade, Exposure 1, with an Identification Index of not less than 24/0
2.2.1.2 Structural-Use Panel: Sheathing grade with durability equivalent to Exposure 1, Span Rating of 24/0 or greater.
2.3 ROUGH HARDWARE: Unless otherwise indicated or specified, rough hardware shall be of the type and size necessary for the project requirements. Sizes, types, and spacing of fastenings of manufactured building materials shall be as recommended by the product manufacturer unless otherwise indicated or specified. Rough hardware exposed to the weather or embedded in or in contact with preservative treated wood, exterior masonry, or concrete walls or slabs shall be zinc-coated.
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ROUGH CARPENTRY
2.3.1 Bolts, Nuts, Studs, and Rivets: ANSI B18.2.1, ANSI B18.5, ANSI B18.2.2, and ASTM A687. Provide a flat washer under each bolt head and a flat and lock washers under each nut.
2.3.2 Lag Screws and Lag Bolts: ANSI B18.2.1.
2.3.3 Wood Screws: ANSI B18.6.1.
2.3.4 Joist Hangers: Steel or iron, zinc coated, sized to fit the supported member, of sufficient strength to develop the full strength of the supported member, and furnished complete with any special nails required.
2.3.5 Tie Straps: For joists supported by the lower flange of steel beams, provide 1/8-inch by 1-1/2-inch steel strap, 2-feet long , except as indicated otherwise.
2.3.6 Joist Anchors: For joists supported by masonry walls, provide anchors 3/16-inch by 1- 1/2-inch steel tee or strap, bent and of length to provide 4 inches embedment into wall and 12 inches along joist except as indicated otherwise. For joists parallel to masonry or concrete walls, provide anchors 1/4-inch by 1-1/4-inch minimum cross-sectional area, steel strap, length as necessary to extend over top of first three joists and into wall 8 inches, and with wall end of bend or pin type , except as indicated otherwise.
2.3.7 Door Buck Anchors: Metal anchors, 1/8-inch by 1-1/4-inch steel, 12 inches long, with ends bent 2 inches , except as indicated otherwise. Anchors shall be screwed to the backs of bucks and built into masonry or concrete. Locate 8 inches above sills and below heads and not more than 24 inches intermediately between. Anchorage of bucks to steel framing shall be as necessary to suit the conditions.
2.3.8 Metal Bridging: Where not indicated or specified otherwise, No. 16 U.S. Standard gauge, cadmium-plated or zinc-coated.
2.3.9 Toothed Rings and Shear Plates: NFP NDS.
2.3.10 Beam Anchors: Steel U-shaped strap anchors 1/4-inch thick by 1-1/2 inches wide , except as indicated otherwise.
6.19 06100-8 394.107.001 SECTION 06100
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2.3.11 Metal Framing Anchors: Construct anchors to the configuration shown using hot dip zinc-coated steel conforming to ASTM A525, coating designation G90. Except where otherwise shown, Steel shall be not lighter than 18 gauge. Special nails supplied by the manufacturer shall be used for all nailing.
PART 3 - EXECUTION
3.1 INSTALLATION: Conform to NFP WCD1 unless otherwise indicated or specified. Fit framing lumber and other rough carpentry, set accurately to the required lines and levels, and secure in place in a rigid manner. Do not splice framing members between bearing points. Set joists, rafters, and purlins with their crown edge up. Faces of framing members which will receive gypsum wallboard shall not vary more than 1/8 inch from the plane of the faces of adjacent framing, bridging, or furring members. Frame members for the passage of pipes, conduits, and ducts. Do not cut or bore structural members for the passage of ducts or pipes without approval. Reinforce all members damaged by such cutting or boring by means of specially formed and approved sheet metal or bar steel shapes, or remove and provide new, as approved. Provide as necessary for the proper completion of the work all framing members not indicated or specified. Spikes, nails, and bolts shall be drawn up tight. Timber connections and fastenings shall conform to NFP NDS. Use slate or steel shims when leveling joists, beams, and girders on masonry or concrete. Do not use shimming on wood or metal bearings.
3.1.1 Sills: Set sills level and square and wedge with steel or slate shims; point or grout with non-shrinking cement mortar to provide continuous and solid bearing. Anchor sills to the foundations as indicated. Where sizes and spacing of anchor bolts are not indicated, provide not less than 5/8-inch diameter bolts at all corners and splices and space at a maximum of 6 feet o.c. between corner bolts. Provide at least two bolts for each sill member. Lap and splice sills at corners and bolt through the laps or butt the ends and through-bolt not more than 6 inches from the ends. Provide bolts with plate washers and nuts. Bolts in exterior walls shall be zinc-coated.
3.1.1.1 Anchors in Masonry: Except where indicated otherwise, Embed anchor bolts not less than 15 inches in masonry unit walls and provide each with a nut and a 2-inch diameter washer at bottom end. Fully grout bolts with mortar.
3.1.1.2 Anchors in Concrete: Except where indicated otherwise, Embed anchor bolts not less than 8 inches in poured concrete walls and provide each with a nut and a 2-inch diameter washer at bottom end. A bent end may be substituted for the nut and washer; bend shall be not less than
6.19 06100-9 394.107.001 SECTION 06100
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90 degrees. Powder-actuated fasteners spaced 3 feet o.c. may be provided in lieu of bolts for single thickness plates on concrete.
3.1.2 Beams and Girders: Set beams and girders level and in alignment and anchor to bearing walls, piers, or supports with U-shaped steel strap anchors. Embed anchors in concrete or masonry at each bearing and through-bolt to the beams or girders with not less than two bolts. Provide bolts not less than 1/2 inch in diameter and with plate washers under heads and nuts. Install beams and girders not indicated otherwise with 8-inch minimum end bearing on walls or supports. Install beams and girders into walls with 1/2-inch clearance at the top, end, and sides or standard steel wall-bearing boxes. Provide joints and splices over bearings only and bolt or spike together.
3.1.3 Joists: Provide joists of the sizes and spacing indicated, accurately and in alignment, and of uniform width. Joists shall have full bearing on sills, plates, beams, girders, and trusses; provide laps over bearing only and spike. Where joists are of insufficient length to produce a 12-inch lap, butt joists over bearing and provide wood scabs 2 inches thick by depth of joists by 24 inches long or metal straps 1/4 inch by 1-1/2 inch by not less than 18 inches long nailed to each joist with not less than four 10-penny nails, or approved sheet metal connectors installed in accordance with the manufacturer's recommendations. Provide joists built into masonry with a beveled fire cut so that the top of the joist does not enter the wall more than one inch or standard steel wall bearing boxes. Provide metal hangers for joists framing into the side of headers, beams, or girders. When a portion of the joist extends above the top flange of a steel beam or girder, provide a 3/8-inch space between the top flange and the extended portion of the joists to allow for shrinkage of joists. The minimum joist end bearing shall be 4 inches, and joists built into concrete or masonry shall have a 1/2-inch minimum clearance at the top, end, and sides. For joists approved to be bored for the passage of pipes or conduits, bore through the neutral axis of the joist. Provide steel joist hangers of proper size and type to receive the ends of all framed joists.
3.1.3.1 Doubled Joists: Provide under bearing walls and partitions running parallel with the floor joists, around stairways, and at other openings where joists are cut and framed. Double, space for clearance, block apart 4 feet on center, rigidly frame, and spike together joists under partitions that are to receive ducts, pipes, and conduits.
3.1.3.2 Tie Straps: For joists supported by the lower flange of steel beams, provide straps at every fourth joist and the corresponding fourth joist on the opposite side. Tie joists across the top of the steel beam with a steel strap. Form straps to lie flat across the top of the beam and
6.19 06100-10 394.107.001 SECTION 06100
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twist at the ends to provide flat contact with the side of each joist. Nail each strap at each end with three 10-penny nails spaced 2 inches o.c.
3.1.3.3 Joist Anchors: Provide anchors for each fourth joist supported by a masonry wall. Build wall end of anchors into the wall. Nail anchor to the joist with three 10-penny nails spaced 2 inches o.c. Anchor the first three joists parallel to concrete or masonry walls at bridging points, but not less than 8 feet o.c. from end walls. Let anchors into the tops of each joist and spike to the top of joist with one 10-penny nail. Extend anchors at least 4inches into the wall.
3.1.4 Bridging: Provide bridging for floor and ceiling joists and for roof rafters having slopes of less than 4 inches in 12 inches. Locate bridging as indicated and as specified herein. Provide bridging for spans greater than 6 feet, but do not exceed 8-feet maximum spacing between rows of bridging. Install rows of bridging uniformly. Provide metal or wood cross-bridging, except where solid bridging is indicated. Do not nail the bottom end of cross bridging until the subfloor has been laid.
3.1.4.1 Wood Cross Bridging: Provide wood cross bridging not less than 1 by 3 inches. Nail wood cross bridging at each end with two 8-penny nails for one-inch thick material and three 8-penny nails for 2-inch thick material.
3.1.4.2 Metal Cross Bridging: Shall be the manufacturer's standard product, not less than 16 gauge before forming and coating. Metal bridging shall be the compression type, lodged into or nailed to the wide faces of opposite joists at points diagonally across from each other near the bottoms and tops of joists.
3.1.4.3 Fire Stops: Provide fire stops for wood-framed walls and partitions and for furred spaces of concrete or masonry walls at each floor level and at the ceiling line in the top story. Where fire stops are not automatically provided by the framing system used, they shall be formed of closely fitted wood blocks of nominal 2-inch thick material.
3.1.5 Trusses: Metal plate connected wood trusses shall be handled and erected in accordance with TPI HET and braced in accordance with TPI BWT.
3.1.6 Plywood and Structural-Use Panel Roof Sheathing: Install with the grain of the outer plies or long dimension at right angles to supports. Stagger end joints and locate over the center lines of supports. Allow 1/8-inch spacing at panel ends and 1/4 inch at panel edges. Nail panels
6.19 06100-11 394.107.001 SECTION 06100
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with 8-penny common nails or 6-penny annular rings or screw-type nails spaced 6 inches o.c. at supported edges and 12 inches o.c. at intermediate bearings.
3.2 MISCELLANEOUS:
3.2.1 Wood Roof Nailers, Edge Strips, Crickets, Curbs, and Cants: Provide sizes and configurations indicated or specified and anchored securely to continuous construction.
3.2.1.1 Roof Nailing Strips: Provide roof nailing strips for roof decks as indicated and]specified herein. Apply nailing strips in straight parallel rows in the direction and spacing indicated. Strips shall besurface applied.
a. Surface-Applied Nailers: Shall be 3 inches wide and of thickness to finish flush with the top of the insulation. Anchor strips securely to the roof deck with powder actuated fastening devices or expansion shields and bolts, spaced not more than 24 inches o.c.. On decks with slopes of one inch or more, provide surface applied wood nailers for securing insulation and for nailing of roofing felts.
3.2.1.2 Roof Edge Strips and Nailers: Provide at perimeter of roof, around openings through roof, and where roofs abut walls, curbs, and other vertical surfaces. Except where indicated otherwise, nailers shall be 6 inches wide
3.2.1.3 Crickets, Cants, and Curbs: Provide wood saddles or crickets, cant strips, curbs for scuttles and ventilators, and wood nailers bolted to tops of concrete or masonry curbs and at expansion joints, as indicated, specified, or necessary and of lumber.
3.2.2 Rough Wood Bucks: 2-inch nominal thickness. Set wood bucks true and plumb. Anchor bucks to concrete or masonry with steel straps extending into the wall 8 inches minimum. Place anchors near the top and bottom of the buck and space uniformly at 2-foot maximum intervals.
3.2.3 Wood Blocking: Provide proper sizes and shapes at proper locations for the installation and attachment of wood and other finish materials, fixtures, equipment, and items indicated or specified.
3.2.4 Wood Grounds: Provide for fastening wood trim, finish materials, and other items to plastered walls and ceilings. Install grounds in proper alignment and true with an 8-foot straightedge.
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3.2.5 Wood Furring: Provide where shown and as necessary for facing materials specified. Except as shown otherwise, furring strips shall be one inch by 3 inches, continuous, and spaced 16 inches o.c. Erect furring vertically or horizontally as necessary. Nail furring strips to masonry. Do not use wood plugs. Provide furring strips around openings, behind bases, and at angles and corners. Furring shall be plumb, rigid, and level and shall be shimmed as necessary to provide a true, even plane with surfaces suitable to receive the finish required. Form furring for offsets and breaks in walls or ceilings on 1-inch by 4-inch wood strips spaced 16 inches o.c.
3.2.6 Wood Bumpers: Dress to the sizes indicated, and bevel edges. Bore, countersink, and bolt bumpers in place.
3.2.7 Temporary Closures: Provide with hinged doors and padlocks and install during construction at exterior doorways and other ground level openings that are not otherwise closed. Cover windows and other unprotected openings with polyethylene or other approved material, stretched on wood frames. Provide dustproof barrier partitions to isolate areas as directed.
3.2.8 Wood Sleepers: Run wood sleepers in lengths as long as practicable and stagger end joints in adjacent rows.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - ROUGH CARPENTRY:
4.1.1 Measurement for Rough Carpentry shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - ROUGH CARPENTRY:
4.2.1 For Rough Carpentry, not included in other unit or lump sum price items, payment for Rough Carpentry will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 06100-13 394.107.001 SECTION 07230
PERIMETER AND UNDER-SLAB INSULATION
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Perimeter and Under-Slab Insulation, as shown on the Plans, as specified, and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American Society for Testing and Materials (ASTM) Publications:
C552 Cellular Glass Thermal Insulation
C578 Rigid, Cellular Polystyrene Thermal Insulation
C591 Unfaced Preformed Rigid Cellular Polyisocyanurate Thermal Insulation
C1289 Faced Rigid Cellular Polyisocyanurate Thermal Insulation Board
D2822 Asphalt Roof Cement
F1667 Driven Fasteners: Nails, Spikes and Staples
1.3 SUBMITTALS:
1.3.1 Manufacturer's Catalog Data: Manufacturer's Data: Include descriptive literature, and recommended instructions on installation methods and procedures for the following:
a. Insulation b. Asphalt roof cement
1.4 DELIVERY AND STORAGE: Deliver materials to the site in the original sealed packages bearing the manufacturer's name and designation, specification number, type, and class. Protect material from damage during construction.
6.19 07230-1 394.107.001 SECTION 07230
PERIMETER AND UNDER-SLAB INSULATION
PART 2 - PRODUCTS
2.1 MATERIALS:
2.1.1 Insulation: ASTM C578 polystyrene board, extruded closed cell. Thickness indicated.
2.1.1.1 Perimeter Insulation: ASTM C578, Type IV, minimum compressive strength of 25 pounds per square inch at 10 percent deformation.
2.1.1.2 Continuous Under-Slab Insulation – High Load (Garage): ASTM C578, Type V, minimum compressive strength of 100 pounds per square inch at 5 percent deformation.
2.1.2 Asphalt Roof Cement: ASTM D2822.
2.1.3 Masonry Nails: ASTM F1667, Type I, Style 11, 17, or 27.
2.1.4 Clips: Type as recommended by insulation manufacturer and approved.
PART 3 - EXECUTION
3.1 INSTALLATION:
3.1.1 Insulation on Foundation Walls: Provide insulation on the interior side of the perimeter foundation walls that are backfilled and have slab on grade. Extend insulation from top edge of slab to not less than two feet below grade. Fasten insulation to the wall with asphalt roof cement, or clips.
3.1.2 Insulation Under Slab: Provide insulation horizontally under slab on grade a distance of two feet from the inside surface of the exterior foundation walls. Insulation shall be firmly supported on top of the subgrade under slab and at slab edge.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - PERIMETER AND UNDER-SLAB INSULATION:
4.1.1 Measurement for Perimeter and Under-Slab Insulation shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
6.19 07230-2 394.107.001 SECTION 07230
PERIMETER AND UNDER-SLAB INSULATION
4.2 PAYMENT - PERIMETER AND UNDER-SLAB INSULATION:
4.2.1 For Perimeter and Under-Slab Insulation, not included in other unit or lump sum price items, payment for Perimeter and Under-Slab Insulation will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 07230-3 394.107.001 SECTION 07232
CEILING, WALL, AND FLOOR INSULATION
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Ceiling, Wall, and Floor Insulation, as shown on the Plans, as specified, and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American Society for Testing and Materials (ASTM) Publications:
C423 Sound Absorption and Sound Absorption Coefficients by the Reverberation Room Method
C578 Rigid Cellular Polystyrene Thermal Insulation
C612 Mineral Fiber Block and Board Thermal Insulation
C665 Mineral Fiber Blanket Thermal Insulation for Light Frame Construction and Manufactured Housing
C1289 Faced Rigid Cellular Polyisocyanurate Thermal Insulation Board
D4397 Polyethylene Sheeting for Construction, Industrial, and Agricultural Applications
E84 Surface Burning Characteristics of Building Materials
E96 Water Vapor Transmission of Materials
1.2.2 Federal Specifications (FS):
HH-I-530 Insulation Board, Thermal, Unfaced Polyurethane or Polyisocyanurate
6.19 07232-1 394.107.001 SECTION 07232
CEILING, WALL, AND FLOOR INSULATION
HH-I-1972-1 Insulation Board, Thermal, Polyurethane or Polyisocyanurate faced with Aluminum on Both Sides of the Foam
1.3 SUBMITTALS: Submit the following.
1.3.1 Manufacturer's Catalog Data:
a. Insulation b. Vapor retarder c. Adhesive d. Duct tape
1.4 DELIVERY AND STORAGE: Deliver materials to the site in the original sealed wrapping bearing manufacturer's name and brand designation, specification number, type, grade, R-value, and class. Store and handle to protect materials from damage. Do not allow insulation materials to become wet, soiled, or covered with ice or snow. Comply with manufacturer's recommendations for handling, storage, and protection during installation.
PART 2 - PRODUCTS
2.1 THERMAL RESISTANCE VALUE (R-VALUE): As indicated on Contract Drawings.
2.2 BATT OR BLANKET INSULATION: ASTM C665, Type I, blankets without membrane coverings and Type II, PSK blankets or Type III, FSK blankets. Type I, with a flame spread of 10 or less and a smoke developed rating of 10 or less when tested in accordance with ASTM E84. Type II and Type III shall be Class A, with a flame spread of 25 or less and a smoke developed rating of 50 or less when tested in accordance with ASTM E84.
2.3 SILL SEALER INSULATION: ASTM C665, Type I.
2.4 BLOCK OR BOARD INSULATION:
2.4.1 Polystyrene: ASTM C578, Type IV, except a flame spread rating of 75 or less and a smoke developed rating of 450 or less when tested in accordance with ASTM E84.
6.19 07232-2 394.107.001 SECTION 07232
CEILING, WALL, AND FLOOR INSULATION
2.4.1.1 Aged R-Value for design basis:
a. 1/2 Inch Thick: R = 3.2 @ 40 degrees F and 3.0 @ 75 degrees F. b. 1 Inch Thick: R = 5.4 @ 40 degrees F and 5.0 @ 75 degrees F.
R-value to be as indicated on Contract Drawings.
2.4.1.2 Edges and Ends: Square or tongue-and-groove at manufacturer’s option.
2.4.2 Polyisocyanurate or Polyurethane Board: FS HH-I-1972/1.
2.4.3 Mineral Fiber: Glass or other inorganic fibers and resinous binders formed into flexible blankets, batts or rolls; ASTM C 665.
2.4.3.1 R-Value for design basis:
a. 3-1/2 or 3-5/8 Inches Nominal Thickness: R = 11.0. b. 9-1/2 Inches Nominal Thickness: R = 30.0.
R-value to be as indicated on Contract Drawings.
2.4.3.2 Type II, Class C - Blankets with a non-reflective barrier membrane covering one principal face.
2.5 VAPOR RETARDER: ASTM D4397, 6-mil thick polyethylene sheeting with a water vapor permeance of 1 perm or less when tested in accordance with ASTM E96. Vapor retarder shall be flame retardant with a flame spread of 25 or less and a smoke developed rating of 150 or less when tested in accordance with ASTM E84.
2.6 ACCESSORIES:
2.6.1 Adhesive: As recommended by the insulation manufacturer.
2.6.2 Duct Tape: As recommended by the insulation manufacturer.
2.7 ACOUSTICAL VALUES: ASTM C423.
6.19 07232-3 394.107.001 SECTION 07232
CEILING, WALL, AND FLOOR INSULATION
PART 3 - EXECUTION
3.1 PREPARATION OF SURFACES: Surfaces shall be clean, dry, and free of any projections.
3.2 INSTALLATION OF BATT OR BLANKET INSULATION:
3.2.1 Ceiling: Do not place insulation closer than 3 inches from the sides of recessed lighting fixtures and heat producing devices or within 24 inches of the top of such fixtures and devices. Place insulation under wiring occurring across joists. Pack insulation into narrowly spaced framing. Do not block flow of air through soffit vents. Place insulation to the outside (cold side) of all pipes. Place insulation with affixed vapor retarder towards the interior (warm-in-winter) side of the construction.
3.2.1.1 Installation at Bridging and Cross Bracing: Insulate bridging and cross bracing by splitting a batt or blanket vertically at the center and packing one half into each opening. Butt insulation at the bridging and cross bracing; fill in the bridged area with loose or scrap insulation.
3.2.1.2 Installation at Ceiling Trusses: Size insulation to the width of the joist spacing. Place insulation which has affixed vapor retarder with vapor retarder towards the interior (warm-in-winter) side of the construction. Staple flanges flush with face of truss (face method) 6-inch intervals. Avoid gaps and bulges in insulation during stapling. Overlap both flanges when using the face method. For insulation without facing, a friction fit is sufficient to hold it in place when installed from above with the ceiling in place. When installed from above, cover the entire ceiling with a separate vapor retarder as specified herein.
3.2.2 Wall: Place insulation with affixed vapor retarder with vapor retarder towards the interior (warm-in-winter) side of the construction. Apply insulation around and to the rear of electrical devices. Place insulation to the outside (cold side) of all pipes.
3.2.2.1 Installation at Sill: Size sill sealer insulation and place insulation over top of masonry or concrete perimeter walls or concrete perimeter floor slab on grade. Fasten sill plate over insulation.
3.2.2.2 Installation at Bridging and Cross Bracing: Insulate bridging and cross bracing by splitting batt or blanket vertically at the center and packing one half into each opening.
6.19 07232-4 394.107.001 SECTION 07232
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3.3 INSTALLATION OF BLOCK OR BOARD INSULATION:
3.3.1 Walls: Apply insulation to the rear of electrical devices. Place insulation to the outside (cold side) of all pipes.
3.3.1.1 Installation at Wood, Metal, and Insulated Furring Members: Install insulation between members as recommended by the insulation manufacturer.
3.3.1.2 Adhesive Attachment on Concrete and Masonry Walls: Apply adhesive to the wall and completely cover wall with insulation using the full back bed method or the spot method with at least six spots, located at each corner and mid-points of each of the longer sides having a diameter of approximately 4 inches or as recommended by the insulation manufacturer. Use the full back method for insulation less than one square foot. Butt all edges of insulation and seal edges with tape.
3.4 INSTALLATION OF VAPOR RETARDER: Apply a continuous retarder on the interior side (warm-in-winter) of the ceiling and wall construction as recommended by the insulation manufacturer. Repair punctures or tears with duct tape. Lap all seams and joints a minimum of 6 inches.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - CEILING, WALL, AND FLOOR INSULATION:
4.1.1 Measurement for Ceiling, Wall, and Floor Insulation shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - CEILING, WALL, AND FLOOR INSULATION:
4.2.1 For Ceiling, Wall, and Floor Insulation, not included in other unit or lump sum price items, payment for Ceiling, Wall, and Floor Insulation will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 07232-5 394.107.001 SECTION 07410
PREFORMED METAL ROOFING AND SIDING
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Preformed Metal Roofing And Siding, as shown on the Plans, and/or as specified.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 Federal Specification (Fed. Spec.):
TT-C-1796A Caulking Compounds, Metal Seam and Wood Seam
1.2.2 Military Specification (Mil. Spec.):
MIL-S-4174B Steel Sheet and Strip, Flat, Aluminum Coated, Low Carbon
1.2.3 American Society for Testing and Materials (ASTM) Publications:
A446 Steel Sheet, Zinc-Coated (Galvanized) by the Hot-Dip Process, Structural (Physical) Quality
A526 Steel Sheet, Zinc-Coated (Galvanized) by the Hot-Dip Process, Commercial Quality
A792 General Requirements for Steel Sheet, Aluminum-Zinc Alloy-Coated by the Hot-Dip Process
C578 Preformed, Cellular Polystyrene Thermal Insulation
C591 Unfaced Preformed Rigid Cellular Polyurethane Thermal Insulation
6.19 07410-1 394.107.001 SECTION 07410
PREFORMED METAL ROOFING AND SIDING
1.3 DEFINITIONS: As used in section.
1.3.1 Sheet: Flat metal sheet which is relatively thin, rectangular in cross-section and form, protected from corrosion by a metallic-coating bonded to the base metal, is produced in commercial sizes, and usually furnished in coiled lengths for further processing.
1.3.2 Finish Coating System: Factory-applied, organic coating system which is applied over sheet.
1.3.3 Corrugated Sheet: Sheet with finish coating system which is bent into standard corrugated shapes by roll forming.
1.3.4 Panel: One of a series of standard-sized units produced by factory cutting a longer length of corrugated sheet, ready for installation as preformed metal roofing or siding.
1.4 SUBMITTALS:
1.4.1 Manufacturer’s Data:
1.4.1.1 Manufacturer's Data: Catalog cuts, technical data sheets and descriptive literatures for the following:
a. Sheets b. Panels c. Accessories d. Fasteners
1.4.2 Shop Drawings (Insulated Coated Steel):
a. Panel and fastener layouts b. Joint c. Corners d. Supports e. Anchorages f. Trim g. Flashing h. Closures and special details
6.19 07410-2 394.107.001 SECTION 07410
PREFORMED METAL ROOFING AND SIDING
1.4.3 Color Sample: One sample of each color indicated. When colors are not indicated, submit not less than six different samples of manufacturer's standard colors for selection.
1.5 DELIVERY AND STORAGE: Deliver, store, and handle panels and other manufactured products to prevent damage. Stack materials stored on the site on platforms or pallets and cover with tarpaulins or other suitable weathertight covering. Store panels so that water which might have accumulated during transit or storage will drain off; do not store the panels in contact with materials that might cause staining. Inspect the panels upon arrival to the job site; if wet, remove the moisture and restack and protect the panels until used.
PART 2 - PRODUCTS
2.1 ROOFING AND SIDING PANELS: When subjected to full design loads, wall panels shall not deflect more than 1/120 of their clear span, and roof panels shall not deflect more than 1/180 of their clear span, but in no case shall the thickness of the sheets for the panels be less than specified. Where gauges are specified, they are subject to normal manufacturing tolerances.
2.1.1 Coated Steel:
2.1.1.1 Panels shall be type having a cross sectional profile and depth as indicated. Form sheets from steel conforming to ASTM A446, Structural Grade A with a galvanized coating conforming to ASTM A526, Coating Class G-90. Sheets shall be not lighter than 26 U.S. Standard Gauge.
2.1.1.2 Finish Coating System: Factory-applied, silicone polyester minimum total dry film thickness of 1.0 mil, available in a minimum of six manufacturer's standard colors. Provide finish coating system on both faces. Color of exterior face shall be as selected from manufacturer's standard colors. Color of interior face shall be manufacturer's standard.
2.1.2 Insulated Coated Steel:
2.1.2.1 Panels shall be interlocking concealed type having a cross sectional profile and depth as indicated with a plastic foam core. Exterior and interior sheets shall be no lighter than 26 U.S. Standard Gauge.
2.1.2.2 Plastic Foam Core:
6.19 07410-3 394.107.001 SECTION 07410
PREFORMED METAL ROOFING AND SIDING
a. Rigid Polyurethane Foam: ASTM C591, Type 1 or 2, foamed-in-place or in board form, with an oxygen index of not less than 22 percent when tested in accordance with ASTM D2863; or
b. Rigid Polystyrene Foam Board: ASTM C578, Type I or II.
2.1.2.3 Finish Coating System: Factory-applied, minimum total dry film thickness of 1.0 mil, available in a minimum of six manufacturer's standard colors. Provide a polyvinyldene fluoride (PVF2) finish coating system on the exterior face. The interior face shall receive a silicone polyester coating system. Concealed surfaces receive an acrylic wash coat applied to a minimum total dry film thickness of 0.20 mil. Colors shall be as selected from manufacturer's standard colors.
2.1.3 Accessories: Sheet metal flashings, trim, moldings, closure strips, caps, and other similar sheet metal accessories used in conjunction with preformed metal panels shall be made of the same material and finish as used for the panels, except that such accessories which will be concealed after installation, may be provided without the finish if they are aluminum- or zinc-coated steel. Thickness of the metal shall be not less than that used for the panels. Molded closure strips shall be closed-cell or solid-cell synthetic rubber, neoprene, or polyvinyl chloride premolded to match the configurations of the preformed metal panels.
2.1.4 Fasteners: Fasteners for attaching panels to structural supports and to adjoining panels shall be as approved and in accordance with the manufacturer's recommendations. Unless specified otherwise, the fasteners shall be self-tapping screws. Design the fastening system to withstand the design loads indicated. Fasteners shall be Series 305 stainless steel or aluminum. Fasteners, with the exception of those having integral hexagonal washer heads and those having aluminum drive caps, shall have composite metal and neoprene washers. Fasteners having integral hexagonal washer heads and fasteners having aluminum drive caps shall have polychloroprene washers. Heads of screws or bolts exposed on exterior face of factory-finished wall shall be nylon headed to match color of wall.
2.1.4.1 Screws: Not less than No. 14 diameter self-tapping type or self-drilling and self-tapping type.
2.1.4.2 Powder-Actuated Fasteners: Provide fasteners of the type to be used with powder-actuated tools, and with a shank diameter of adequate size to support loads imposed. Shank length of fasteners shall be not less than 1/2 inch for fastening panels to steel and not less than one inch for fastening panels to concrete. Fasteners for securing wall panels shall have threaded studs suitable for attaching approved color-coated nuts or caps.
6.19 07410-4 394.107.001 SECTION 07410
PREFORMED METAL ROOFING AND SIDING
2.1.5 Joint Sealing Material: Fed. Spec. TT-C-1796, Type II, Class B ribbon form sealant, except that it shall not contain bituminous materials.
PART 3 - EXECUTION
3.1 INSTALLATION: In accordance with the manufacturer's approved installation instructions, except as specified otherwise. Panels shall be in full and firm contact with supports and with each other at side and end laps. Where panels are cut in the field, or where any of the factory-applied coatings are damaged in handling or installation, they shall, after the necessary repairs have been made with material of the same type and color as the finish coating, be approved before installation. Seal completely all cut ends and edges, including those at openings through the panels. Correct defects in the materials. Remove defective materials which cannot be corrected and provide non-defective materials. Provide molded closure strips where indicated and whenever panels terminate with open ends after installation.
3.1.1 Wall Panels: Apply panels with the configurations in a vertical position. Provide panels in the full wall heights from base to eave with no horizontal joints except at the junctions of door frames, louver panels, and similar locations. Seal side and end laps with joint sealing material. Flash seal walls at the base, at the top, around windows, door frames, framed louvers, and other similar openings. Place closure strips, flashing, and sealing material to achieve complete weathertightness. Flashing will not be required where approved interlocking, concealed-type side joints with concealed fasteners for wall panels are used.
3.1.2 Roof Panels: Apply roofing panels with the configurations parallel to the slope of the roof. Provide roofing panels in the longest lengths obtainable, with end laps occurring only at purlins and structural members or full lengths from ridge or ridge panel to eaves, with no transverse joints except at the junction of ventilators, curbs, skylights, chimneys, and similar openings. Lay side laps away from the prevailing wind and seal side and end laps with joint sealing material. Flash seal the roof at the ridge, at eaves and rakes, at projections through the roof, and elsewhere as necessary. Place closure strips, flashing, and sealing material to achieve complete weathertightness. Minimum side lap shall be interlocking rib. End laps shall be not less than 8 inches and shall occur only over purlins and structural members.
3.1.3 Flashings: Flashings and related closures and accessories in connection with the preformed metal panels shall be provided where indicated and as necessary to provide a watertight installation. Details of installation which are not indicated shall be in accordance with the panel manufacturer's printed instructions and details or approved shop drawings. Installation shall allow for expansion and contraction of flashing.
6.19 07410-5 394.107.001 SECTION 07410
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3.1.4 Fasteners: Fastener spacings shall be in accordance with the manufacturer's recommendations and as necessary to withstand the design loads indicated. Install fasteners in valleys or crowns as recommended by the manufacturer of the panel being used. Install fasteners in straight lines within a tolerance of 1/2 inch in the length of a bay. Drive exposed, penetrating-type fasteners normal to the surface and to a uniform depth to seat washers with gaskets and drive so as not to damage factory-applied coating. Exercise extreme care in drilling pilot holes for fastenings to keep drills perpendicular and centered in valleys or crowns, as applicable. After drilling, remove metal filings and burrs from holes prior to installing fasteners and washers. Torque used in applying fasteners shall not exceed that recommended by the manufacturer. Remove panels damaged by over torqued fastenings, and provide new panels. Remove metal shavings and filings from roofs on completion to prevent rusting and discoloration of the panels.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - PREFORMED METAL ROOFING AND SIDING:
4.1.1 Measurement for Preformed Metal Roofing And Siding shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - PREFORMED METAL ROOFING AND SIDING:
4.2.1 For Preformed Metal Roofing And Siding, not included in other unit or lump sum price items, payment for Preformed Metal Roofing And Siding will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 07410-6 394.107.001 SECTION 07600
FLASHING AND SHEET METAL
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Flashing and Sheet Metal, as shown on the Plans, as specified, and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American Society for Testing and Materials (ASTM) Publications:
B209 Aluminum and Aluminum-Alloy Sheet and Plate
B221 Aluminum and Aluminum-Alloy Extruded Bar, Rod, Wire, Shape, and Tube
D41 Asphalt Primer Used in Roofing, Dampproofing and Waterproofing
D1784 Rigid Poly (Vinyl Chloride) (PVC) Compounds and Chlorinated Poly (Vinyl Chloride) (CPVC) Compounds
D2822 Asphalt Roof Cement
D4022 Coal Tar Roof Cement
1.2.2 American Welding Society, Inc. (AWS) Publication:
D1.2 Structural Welding Code, Aluminum
1.2.3 Federal Specifications (FS):
QQ-L-201 Lead Sheet
UU-B-790 Building Paper, Vegetable Fiber: (Kraft, Waterproofed, Water Repellent and Fire Resistant)
6.19 07600-1 394.107.001 SECTION 07600
FLASHING AND SHEET METAL
1.2.4 Sheet Metal and Air Conditioning Contractors' National Association, Inc. (SMACNA) Publication:
ASMM Architectural Sheet Metal Manual
1.3 SUBMITTALS: Submit the following.
1.3.1 Drawings:
a. Gutters and downspouts
b. Building expansion joints
c. Gravel stops and fascias
d. Flashing for roof drains
e. Base and cap flashing (counterflashing)
f. Flashing at roof penetrations
g. Reglets
h. Copings
Indicate thicknesses, dimensions, fastenings and anchoring methods, expansion joints, and other provisions necessary for thermal expansion and contraction. Scaled manufacturer's catalog data may be submitted for factory fabricated items.
1.4 DELIVERY, HANDLING, AND STORAGE: Package and protect materials during shipment. Uncrate and inspect materials for damage, dampness, and wet-storage stains upon delivery to the job site. Remove from the site and replace damaged materials that cannot be restored to like-new condition. Handle sheet metal items to avoid damage to surfaces, edges, and ends. Store materials in dry, weathertight, ventilated areas until immediately before installation.
6.19 07600-2 394.107.001 SECTION 07600
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PART 2 - PRODUCTS
2.1 MATERIALS: Furnish sheet metal items in 8 to 10-foot lengths. Single pieces less than 8 feet long may be used to connect to factory-fabricated inside and outside corners, and at ends of runs. Provide accessories and other items essential to complete the sheet metal installation. These accessories shall be made of the same materials as the items to which they are applied. Fabricate sheet metal items of the materials specified below and to the gage, thickness, or weight shown in Table I at the end of this Section. Sheet metal items shall have mill finish unless specified otherwise. Where more than one material is listed for a particular item in Table I, each is acceptable and may be used except as follows:
2.1.1 Exposed Sheet Metal Items: Shall be of the same material. The following items shall be considered as exposed sheet metal: gutters, including hangers; downspouts; gravel stops and fascias; cap, valley, steeped, base, and eave flashings and related accessories.
2.1.2 Lead Sheet: FS QQ-L-201, Grade B, minimum weight 4 pounds per square foot.
2.1.3 Aluminum Alloy Sheet and Plate: ASTM B209, form alloy, and temper appropriate for use.
2.1.3.1 Alclad: When fabricated of aluminum, the following items shall be fabricated of Alclad 3003, Alclad 3004, Alclad 3005, clad on one side, unless otherwise indicated.
a. Gutters, downspouts, and hangers
b. Gravel stops and fascias
c. Flashing.
2.1.3.2 Finish: Exposed exterior sheet metal items of aluminum shall have a baked-on, factory-applied color coating of polyvinylidene fluoride (PVF2) or other equivalent fluorocarbon coating applied after metal substrates have been cleaned and pretreated. Finish coating dry-film thickness shall be 0.8 to 1.3 mils, and color shall be as selected by Owner.
2.1.4 Aluminum Alloy, Extruded Bars, Rods, Shapes, and Tubes: ASTM B221.
2.1.5 Polyvinyl Chloride Reglet: ASTM D1784, Type II, 0.075 inch (1.9 mm) minimum thickness.
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2.1.6 Bituminous Plastic Cement: ASTM D2822, Type I; ASTM D4022.
2.1.7 Building Paper: FS UU-B-790, Style 4, Grade B.
2.1.8 Asphalt Primer: ASTM D41.
2.1.9 Through-Wall Flashing: Through-wall flashing for masonry is specified in Section 04200, "Unit Masonry".
2.1.10 Fasteners: Use the same metal or a metal compatible with the item fastened. Use stainless steel fasteners to fasten dissimilar materials.
PART 3 - EXECUTION
3.1 INSTALLATION:
3.1.1 Requirements: Make surfaces to receive sheet metal plumb and true, clean, even, smooth, dry, and free of defects and projections which might affect the application. For installation of items not shown in detail or not covered by specifications, conform to the applicable requirements of SMACNA ASMM, Architectural Sheet Metal Manual. Provide sheet metal flashing in the angles formed where roof decks abut walls, curbs, ventilators, pipes, or other vertical surfaces and wherever indicated and necessary to make the work watertight. Join sheet metal items together as shown in Table II.
3.1.2 Workmanship: Make lines, arrises, and angles sharp and true. Free exposed surfaces from visible wave, warp, and buckle, and tool marks. Fold back exposed edges neatly to form a 1/2-inch hem on the concealed side. Make sheet metal exposed to the weather watertight with provisions for expansion and contraction.
3.1.3 Nailing: Confine nailing of sheet metal generally to sheet metal having a maximum width of 18 inches. Confine nailing or flashing to one edge only. Space nails evenly not over 3 inches on centers and approximately 1/2 inch from edge unless otherwise specified or indicated. Face nailing will not be permitted. Where sheet metal is applied to other than wood surfaces, include in shop drawings, the locations for sleepers and nailing strips required to secure the work. Sleepers and nailing strips are specified in Section 06100, "Rough Carpentry".
3.1.4 Cleats: Provide cleats for sheet metal 18 inches and over in width. Space cleats evenly not over 12 inches on centers unless otherwise specified or indicated. Unless otherwise
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specified, cleats shall be not less than 2 inches wide by 3 inches long and of the same material and thickness as the sheet metal being installed. Secure one end of the cleat with two nails and the cleat folded back over the nailheads. Lock the other end into the seam. Pre-tin cleats for soldered seams.
3.1.5 Loose-Lock Expansion Seams: Not less than 3 inches wide; provide minimum one-inch movement within the joint. Completely fill the joints with the specified sealant, applied at not less than 1/8-inch thick bed. Sealants are specified in Section 07920, "Sealants".
3.1.6 Welding and Mechanical Fastening: Use welding for aluminum of thickness greater than 0.040 inch. Aluminum 0.040 inch or less in thickness shall be butted and the space backed with formed flashing plate; or lock joined, mechanically fastened, and filled with sealant as recommended by the aluminum manufacturer.
3.1.6.1 Welding of Aluminum: Use welding of the inert gas, shield-arc type. For procedures, appearance and quality of welds, and the methods used in correcting welding work, conform to AWS D1.2.
3.1.6.2 Mechanical Fastening of Aluminum: Use No. 12, aluminum alloy, sheet metal screws or other suitable aluminum alloy or stainless steel fasteners. Drive fasteners in holes made with a No. 26 drill in securing side laps, end laps, and flashings. Space fasteners 12 inches maximum on centers. Where end lap fasteners are required to improve closure, locate the end lap fasteners not more than 2 inches from the end of the overlapping sheet.
3.1.7 Protection from Contact with Dissimilar Materials:
3.1.7.1 Aluminum: Aluminum surfaces shall not directly contact other metals except stainless steel, zinc, or zinc coating. Where aluminum contacts another metal, paint the dissimilar metal with a primer followed by two coats of aluminum paint. Where drainage from a dissimilar metal passes over aluminum, paint the dissimilar metal with a non-lead pigmented paint.
3.1.7.2 Wood or Other Absorptive Materials: Paint surfaces that may become repeatedly wet and in contact with metal with two coats of aluminum paint or a coat of heavy-bodied bituminous paint.
3.1.8 Expansion and Contraction: Provide expansion and contraction joints at not more 32-foot intervals for aluminum and at not more than 40-foot intervals for other metals. Where the distance between the last expansion joint and the end of the continuous run is more than half
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the required interval, an additional joint shall be provided. Space joints evenly. Join extruded aluminum gravel stops and fascias by expansion and contraction joints spaced not more than 12 feet apart.
3.1.9 Base Flashing: Lay the base flashings with each course of the roof covering, shingle fashion, where practicable, where sloped roofs abut chimneys, curbs, walls, or other vertical surfaces. Extend up vertical surfaces of the flashing not less than 8 inches and not less than 4 inches under the roof covering. Where finish wall coverings form a counterflashing, extend the vertical leg of the flashing up behind the applied wall covering not less than 6 inches. Overlap the flashing strips with the previously laid flashing not less than 3 inches. Fasten the strips or shingles at their upper edge to the deck, with compatible, large-head roofing nails. Solder end laps and provide for expansion and contraction. Extend the metal flashing over crickets at the up-slope side of vertical surfaces extending through sloping roofs, the metal flashings. Extend the metal flashings onto the roof covering not less than 4.5 inches at the lower side of vertical surfaces extending through the roof decks. Install and fit the flashings so as to be completely weathertight. Base flashing for interior and exterior corners shall be factory-fabricated.
3.1.10 Counterflashing: Except where indicated or specified otherwise, insert counterflashing in reglets located from 9 to 10 inches above roof decks, extend down vertical surfaces over upturned vertical leg of base flashings not less than 3 inches. Fold the exposed edges of counterflashings 1/2 inch. Where stepped counterflashings are required, they may be installed in short lengths or may be of the preformed one-piece type. Provide end laps in counterflashings not less than 3 inches and make it weathertight with plastic cement. Do not make lengths of metal counterflashings exceed 10 feet. Form the flashings to the required shapes before installation. Factory-form the corners not less than 12 inches from the angle. Secure the flashings in the reglets with lead wedges and space not more than 18 inches apart; on short runs, place wedges closer together. Fill calked-type reglets or raked joints which receive counterflashing with calking compound. Calking is covered in Section 07920, "Sealants". Turn up the concealed edge of counterflashings built into masonry or concrete walls not less than 1/4 inch and extend not less than 2 inches into the walls. Install counterflashing to provide a spring action against base flashing.
3.1.11 Metal Reglets: Calked type or friction type reglets shall be factory fabricated with a minimum opening of 1/4 inch and a depth of 1-1/4 inches, as approved.
3.1.11.1 Calked Reglets: Provide with rounded edges and metal strap brackets or other anchors for securing to the concrete forms. Provide reglets with a core to protect them from injury during the installation. Provide built-up mitered corner pieces for internal and external
6.19 07600-6 394.107.001 SECTION 07600
FLASHING AND SHEET METAL
angles. Wedge the flashing in the reglets with lead wedges every 18 inches, calked full and solid with an approved compound.
3.1.11.2 Friction Reglets: Provide with flashing receiving slots not less than 5/8 inch deep, one-inch jointing tongues, and upper and lower anchoring flanges. Insert the flashing the full depth of the slot and lock by indentations made with a dull-pointed tool.
3.1.12 Polyvinyl Chloride Reglets: Rigid polyvinyl chloride reglets may be provided in lieu of metal reglets.
3.1.12.1 Edge Strip: Hook the lower edge of fascias at least 3/4 inch over a continuous strip of the same material bent outward at an angle not more than 45 degrees to form a drip. Nail hook strip to a wood nailer at 6 inches maximum on centers. Where fastening is made to concrete or masonry, use screws spaced 12 inches on centers driven in expansion shields set in the concrete or masonry. Where horizontal wood nailers are slotted to provide for insulation venting, install strips to prevent obstruction of vent slots. Where necessary, install strips over 1/16-inch thick compatible spacer or washers.
3.1.12.2 Joints: Leave open the section ends of gravel stops and fascias 1/4 inch and backed with a formed flashing plate, mechanically fastened in place and lapping each section end a minimum of 4 inches set laps in plastic cement. Face nailing will not be permitted. Install prefabricated aluminum gravel stops and fascias in accordance with the manufacturer's printed instructions and details.
3.1.13 Metal Drip Edge: Provide a metal drip, designed to allow water run-off to drip free of underlying construction, at eaves and rakes prior to the application of roofing shingles. Apply directly on the wood deck at the eaves and over the underlay along the rakes. Extend back from the edge of the deck not more than 3 inches and secure with compatible nails spaced not more than 10 inches on center along upper edge.
3.1.14 Gutters: Field fabricate seamless gutters in manufacturer's standard shape, size as required. Provide gutters complete with mitered corners, end caps, outlets, brackets, and other accessories necessary for installation. Aluminum gutters shall be joined with riveted sealed joints. Install gutters below slope line of the roof so that snow and ice can slide clear. Support gutters on adjustable hangers spaced not more than 30 inches on center or as recommended by the manufacturer. Adjust gutters to slope uniformly to outlets, with high points occurring midway between outlets. Fabricate hangers and fastenings from metals compatible with the gutters.
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3.1.15 Downspouts: Types, shapes and sizes are indicated. Provide complete including elbows and offsets. Provide downspouts in approximately 10-foot lengths. Provide end joints to telescope not less than 1/2 inch and lock longitudinal joints. Provide gutter outlets with wire ball strainers for each outlet. Provide strainers to fit tightly into outlets and be of the same material used for gutters. Keep downspouts not less than one inch away from walls. Fasten to the walls at top, bottom, and at an intermediate point not to exceed 5 feet on centers with leader straps or concealed rack-and-pin type fasteners. Form straps and fasteners of metal compatible with the downspouts.
3.1.15.1 Terminations: Neatly fit into the drainage connection the downspouts terminating in drainage lines, and fill the joints with a Portland cement mortar cap sloped away from the downspout. Provide downspouts terminating in splash blocks with elbow-type fittings.
3.1.16 Open Valley Flashing: Provide valley flashing free of longitudinal seams, of width sufficient to extend not less than 6 inches under the roof covering on each side. Provide a 1/2-inch fold on each side of the valley flashing. Lap the sheets not less than 6 inches in the direction of flow and secure to roofing construction with cleats attached to the fold on each side. Nail the tops of sheets to roof sheathing. Space the cleats not more than 12 inches on centers. Provide exposed flashing not less than 4 inches in width at the top and increase one inch in width for each additional 8 feet in length. Where the slope of the valley is 4.5 inches or less per foot, or the intersecting roofs are on different slopes, provide an inverted V-joint, one inch high, along the center line of the valley; and extend the edge of the valley sheets 8 inches under the roof covering on each side.
3.1.17 Eave Flashing: One piece in width, applied in 8 to 10-foot lengths with expansion joints spaced as specified in paragraph entitled "Expansion and Contraction". Provide a 3/4-inch continuous fold in the upper edge of the sheet to engage cleats spaced not more than 10 inches on centers. Locate the upper edge of flashing not less than 18 inches from the outside face of the building, measured along the roof slope. Fold lower edge of the flashing over and loose-lock into a continuous edge strip on the fascia. Where eave flashing intersects metal valley flashing, secure with one-inch flat locked joints with cleats that are 10 inches on centers. Place eave flashing over underlayment and in plastic bituminous cement.
3.1.18 Expansion Joints: Provide expansion joints for roofs, walls, and floors where indicated and conform to the requirements of Table I.
3.1.19 Flashing at Roof Penetrations and Equipment Supports: Provide metal flashing for all pipes, ducts, and conduits projecting through the roof surface and for equipment supports, guy wire anchors, and similar items supported by or attached to the roof deck.
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FLASHING AND SHEET METAL
3.1.19.1 Single Pipe Vents: "See Table I, footnote (d). Set flange of sleeve in bituminous plastic cement and nail 3 inches on centers. Bend the top of sleeve over and extend down into the vent pipe a minimum of 2 inches. For long runs or long rises above the deck, where it is impractical to cover the vent pipe with lead, use a two-piece formed metal housing. Set metal housing with a metal sleeve having a 4-inch roof flange in bituminous plastic cement and nailed 3 inches on centers. Extend sleeve a minimum of 8 inches above the roof deck and lapped a minimum of 3 inches by a metal hood secured to the vent pipe by a draw band. Seal the area of hood in contact with vent pipe with an approved sealant. Sealants are covered under Section 07920, "Sealants".
3.2 PAINTING: Field-paint sheet metal for separation of dissimilar materials.
3.3 CLEANING: Clean exposed sheet metal work at completion of installation. Remove grease and oil films, handling marks, contamination from steel wool, fittings and drilling debris, and scrub-clean. Free the exposed metal surfaces of dents, creases, waves, scratch marks, and solder or weld marks.
3.4 REPAIRS TO FINISH: Scratches, abrasions, and minor surface defects of finish may be repaired in accordance with the manufacturer's printed instructions and as approved. Repair damaged surfaces caused by scratches, blemishes, and variations of color and surface texture. Replace items which cannot be repaired.
TABLE I. SHEET METAL WEIGHTS AND THICKNESSES
Lead, Pounds Per Square Aluminum, Sheet Metal Items Foot Inch
Building Expansion Joints Cover 16 .032 Waterstop-bellows or flanged, U-type. 16 - Downspouts and leaders 16 .032 Downspout clips and anchors - .040 clip - .125 anchor Downspout straps, 2-inch 48(a) .060 Flashings: Base 20 .040 Cap (Counter-flashing) 16 .032
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FLASHING AND SHEET METAL
Stepped 16 .032 Valley 16 .032 Roof drain 4 Pipe vent sleeve (a) 2.5 Coping - .040 Gravel stops and fascias: Extrusions .075 Sheets, corrugated .032 Sheets, smooth .050 Edge strip .050 Gutters: Gutter section .032 Continuous cleat .032 Hangers, dimensions 1 inch x .080 inch Joint Cover plates .032
(a) 2.5-pound minimum lead sleeve with 4-inch flange. Where lead sleeve is impractical, refer to paragraph titled "Single Pipe Vents" for optional material.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - FLASHING AND SHEET METAL:
4.1.1 Measurement for Flashing and Sheet Metal shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - FLASHING AND SHEET METAL:
4.2.1 For Flashing and Sheet Metal, not included in other unit or lump sum price items, payment for Flashing and Sheet Metal will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 07600-10 394.107.001 SECTION 07920
SEALANTS
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Sealants, as shown on the Plans, and/or as specified.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American Society for Testing and Materials (ASTM) Publication:
C920 Elastomeric Joint Sealants
1.3 SUBMITTALS: Submit the following.
1.3.1 Manufacturer's Catalog Data:
a. Sealants
b. Primers
c. Backstop materials
Data for the sealants shall include shelf life and recommended cleaning solvents.
1.4 ENVIRONMENTAL CONDITIONS: The ambient temperature shall be within the limits of 40 and 100 degrees F when sealant is applied.
1.5 DELIVERY AND STORAGE: Deliver materials to the job site in unopened manufacturers' external shipping containers, with brand names, date of manufacture, color, and material designation clearly marked thereon. Elastomeric sealant containers shall be labeled to identify type, class, grade, and use. Carefully handle and store materials to prevent inclusion of foreign materials or subjection to sustained temperatures exceeding 100 degrees F or less than 40 degrees F.
6.19 07920-1 394.107.001 SECTION 07920
SEALANTS
PART 2 - PRODUCTS
2.1 SEALANTS: Provide sealant that has been tested and found suitable for the substrates to which it will be applied.
2.1.1 Interior Sealant: ASTM C920, Type S or M, Grade NS, Class 12.5, Use NT. Location(s) of sealant shall be as follows:
LOCATION
a. Small voids between walls or partitions and adjacent lockers, casework, shelving, door frames, built-in or surface-mounted equipment and fixtures, and similar items.
b. Perimeter of frames at doors, windows, and access panels which adjoin exposed interior concrete and masonry surfaces.
c. Joints of interior masonry walls and partitions which adjoin columns, pilasters, concrete walls, and exterior walls unless otherwise detailed.
d. Joints between edge members for acoustical tile and adjoining vertical surfaces.
e. Interior locations, not otherwise indicated or specified, where small voids exist between materials specified to be painted.
2.1.2 Exterior Sealant: For joints in vertical surfaces, provide ASTM C920, Type S or M, Grade NS, Class 25, Use NT. For joints in horizontal surfaces, provide ASTM C920, Type S or M, Grade P, Class 25, Use T. Location(s) of sealant shall be as follows:
LOCATION
a. Joints and recesses formed where frames and subsills of windows, doors, louvers, and vents adjoin masonry, concrete, or metal frames. Use sealant at both exterior and interior surfaces of exterior wall penetrations.
b. Joints between new and existing exterior masonry walls.
c. Masonry joints where shelf angles occur.
d. Joints in wash surfaces of stonework.
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SEALANTS
e. Expansion and control joints.
f. Interior face of expansion joints in exterior concrete or masonry walls where metal expansion joint covers are not required.
g. Voids where items pass through exterior walls.
h. Metal reglets, where flashing is inserted into masonry joints, and where flashing is penetrated by coping dowels.
i. Metal-to-metal joints where sealant is indicated or specified.
j. Joints between ends of gravel stops, fascias, copings, and adjacent walls.
2.1.3 Floor Joint Sealant: ASTM C920, Type S or M, Grade P, Class 25, Use T. Location(s) of sealant shall be as follows:
LOCATION
a. Seats of metal thresholds for exterior doors. b. Control and expansion joints in floors, slabs, and walkways.
2.2 PRIMER FOR SEALANT: Provide a nonstaining, quick-drying type and consistency recommended by the sealant manufacturer for the particular application.
2.3 BOND BREAKERS: Provide the type and consistency recommended by the sealant manufacturer for the particular application.
2.4 BACKSTOPS: Provide glass fiber roving or neoprene, butyl, polyurethane, or polyethylene foams free from oil or other staining elements as recommended by sealant manufacturer. Backstop material shall be compatible with sealant. Do not use oakum and other types of absorptive materials as backstops.
2.5 CLEANING SOLVENTS: Provide type(s) recommended by the sealant manufacturer, except for aluminum and bronze surfaces that will be in contact with sealant.
2.6 COLOR: Sealants exposed to view shall match the color of adjacent finished surfaces.
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SEALANTS
PART 3 - EXECUTION
3.1 SURFACE PREPARATION: Surfaces shall be clean, dry to the touch, and free from dirt, frost, moisture, grease, oil, wax, lacquer, paint, or other foreign matter that would tend to destroy or impair adhesion. When resealing an existing joint, remove existing calk or sealant prior to applying new sealant.
3.1.1 Steel Surfaces: Remove loose mill scale by sandblasting or, if sandblasting is impractical or would damage finish work, scraping and wire brushing. Remove protective coatings by sandblasting or using a residue-free solvent.
3.1.2 Aluminum or Bronze Surfaces: Remove temporary protective coatings from surfaces that will be in contact with sealant. When masking tape is used as a protective coating, remove tape and any residual adhesive just prior to sealant application. For removing protective coatings and final cleaning, use nonstaining solvents recommended by the manufacturer of the item(s) containing aluminum or bronze surfaces.
3.2 SEALANT PREPARATION: Do add liquids, solvents, or powders to the sealant. Mix multi-component elastomeric sealants in accordance with manufacturer's instructions.
3.3 APPLICATION:
3.3.1 Joint Width-To-Depth Ratios:
a. Acceptable Ratios:
JOINT WIDTH JOINT DEPTH Minimum Maximum For metal, glass, or other nonporous surfaces:
1/4 inch (minimum) 1/4 inch 1/4 inch over 1/4 inch 1/2 of width Equal to width
For wood, concrete or masonry:
1/4 inch (minimum) 1/4 inch 1/4 inch Over 1/4 inch to 1/2 inch 1/2 of width Equal to width
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Over 1/2 inch to 2 inches 1/2 inch 5/8 inch Over 2 inches (As recommended by sealant manufacturer)
b. Unacceptable Ratios: Where joints of acceptable width-to-depth ratios have not been provided, clean out joints to acceptable depths and grind or cut to acceptable widths without damage to the adjoining work. Grinding shall not be required on metal surfaces.
3.3.2 Backstops: Install backstops dry and free of tears or holes. Tightly pack the back or bottom of joint cavities with backstop material to provide a joint of the depth specified. Install backstops in the following locations:
a. Where indicated.
b. Where backstop is not indicated but joint cavities exceed the acceptable maximum depths specified in paragraph entitled, "Joint Width-to-Depth Ratios".
3.3.3 Primer: Immediately prior to application of the sealant, clean out loose particles from joints. Where recommended by sealant manufacturer, apply primer to joints in concrete masonry units, wood, and other porous surfaces in accordance with sealant manufacturer's instructions. Do not apply primer to exposed finish surfaces.
3.3.4 Bond Breaker: Provide bond breakers to the back or bottom of joint cavities, as recommended by the sealant manufacturer for each type of joint and sealant used, to prevent sealant from adhering to these surfaces. Carefully apply the bond breaker to avoid contamination of adjoining surfaces or breaking bond with surfaces other than those covered by the bond breaker.
3.3.5 Sealants: Provide a sealant compatible with the material(s) to which it is applied. Do not use a sealant that has exceeded shelf life or has jelled and cannot be discharged in a continuous flow from the gun. Apply the sealant in accordance with the manufacturer's instructions with a gun having a nozzle that fits the joint width. Force sealant into joints to fill the joints solidly without air pockets. Tool sealant after application to ensure adhesion. Sealant shall be uniformly smooth and free of wrinkles. Upon completion of sealant application, roughen partially filled or unfilled joints, apply sealant, and tool smooth as specified.
6.19 07920-5 394.107.001 SECTION 07920
SEALANTS
3.4 PROTECTION AND CLEANING:
3.4.1 Protection: Protect areas adjacent to joints from sealant smears. Masking tape may be used for this purpose if removed 5 to 10 minutes after the joint is filled.
3.4.2 Final Cleaning: Upon completion of sealant application, remove remaining smears and stains, and leave the work in a clean and neat condition.
a. Masonry and Other Porous Surfaces: Immediately scrape off fresh sealant that has been smeared on masonry, and rub clean with a solvent as recommended by the sealant manufacturer. Allow excess sealant to cure for 24 hours then remove by wire brushing or sanding.
b. Metal and Other Nonporous Surfaces: Remove excess sealant with a solvent-moistened cloth.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - SEALANTS:
4.1.1 Measurement for Sealants shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - SEALANTS:
4.2.1 For Sealants, not included in other unit or lump sum price items, payment for Sealants will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 07920-6 394.107.001 SECTION 08110
STEEL DOORS AND FRAMES
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Steel Doors and Frames, as shown on the Plans, as specified, and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American Society for Testing and Materials (ASTM) Publications:
A526 Steel Sheet, Zinc-Coated (Galvanized) by the Hot-Dip Process, Commercial Quality
A591 Steel Sheet, Cold-Rolled, Electrolytic Zinc-Coated
C578 Preformed, Cellular Polystyrene Thermal Insulation
C591 Unfaced Preformed Rigid Cellular Polyurethane Thermal Insulation
D2863 Measuring the Minimum Oxygen Concentration to Support Candle-Like Combustion of Plastics (Oxygen Index)
1.2.2 Door and Hardware Institute (DHI) Publications:
A115.1 Preparation for Mortise Locks for 1-3/8 Inch and 1-3/4-Inch Doors
A115.2 Preparation for Bored Locks for 1-3/4 Inch and 1-3/8-Inch Doors
A115.4 Preparation for Lever Extension Flush Bolts
A115.5 Preparation for 181 Series and 190 Series Deadlock Strikes
6.19 08110-1 394.107.001 SECTION 08110
STEEL DOORS AND FRAMES
A115.7 Preparation for Floor Closers -- Light Duty, Center Hung, Single or Double Acting; Center Hung, Single or Double Acting; Offset Hung, Single Acting
A115.12 Preparation for Offset Intermediate Pivots
A115.13 Preparation for Tubular Deadlocks
A115.14 Preparation for Open Back Strikes
1.2.3 Hollow Metal Manufacturers Association (HMMA) Publications:
861 Guide Specifications for Commercial Hollow Metal Doors and Frames
862 Guide Specifications for Commercial Security Hollow Metal Doors and Frames
863 Guide Specifications for Detention Security Hollow Metal Doors and Frames
865 Guide Specifications for Swinging Sound Control Hollow Metal Doors and Frames
1.2.4 Military Specification (MIL):
DOD-P-21035 Paint, High Zinc Dust Content, Galvanizing Repair (Metric)
1.2.5 National Fire Protection Association (NFPA) Publications:
80 Fire Doors and Windows
252 Fire Tests of Door Assemblies
1.2.6 Underwriters Laboratories, Inc. (UL) Publication:
10B Fire Tests of Door Assemblies
6.19 08110-2 394.107.001 SECTION 08110
STEEL DOORS AND FRAMES
1.3 SUBMITTALS: Submit the following.
1.3.1 Manufacturer's Catalog Data:
a. Doors
b. Frames
c. Accessories
Submit manufacturer's descriptive literature for doors, frames, and accessories. Include data and details on door construction, panel (internal) reinforcement, insulation, and door edge construction.
1.3.2 Drawings:
a. Steel doors
Show elevations, construction details, metal gauges, hardware provisions, method of glazing, and installation details.
1.3.3 Schedules:
a. Doors and frames
Submit door and frame locations.
1.4 DELIVERY AND STORAGE: Deliver doors, frames, and accessories undamaged and with protective wrappings or packaging. Strap welded frames in pairs, with one frame inverted, or provide temporary steel spreaders securely fastened to the bottom of each frame. Store doors and frames on platforms under cover in clean, dry, ventilated, and accessible locations, with 1/4-inch airspace between doors. Remove damp or wet packaging immediately, and wipe affected surfaces dry. Replace damaged materials with new.
6.19 08110-3 394.107.001 SECTION 08110
STEEL DOORS AND FRAMES
PART 2 - PRODUCTS
2.1 STANDARD STEEL DOORS: SDI 100, except as specified otherwise. Doors shall be either hollow steel construction or composite construction. Prepare doors to receive hardware specified in Section 08710, "Finish Hardware". Undercut doors where indicated. Exterior doors shall have top edge closed flush. Doors shall be 1-3/4 inches thick, unless otherwise indicated.
2.1.1 Door Grades:
2.1.1.1 Standard Duty Doors: SDI 100 level 2, performance B, seamless, of size(s) and design(s) indicated. Provide where shown.
2.2 SHELVES, LOUVERS, ASTRAGALS, AND MOLDINGS:
2.2.1 Moldings: Provide moldings around glass and louvers. Provide nonremovable moldings on the outside of exterior doors and on the corridor side of interior doors. Other moldings may be stationary or removable. Secure inside moldings to the stationary moldings, or provide snap-on moldings. Muntins shall interlock at intersections and shall be fitted and welded to stationary moldings.
2.3 PLASTIC FOAM CORES:
a. Rigid Polyurethane Foam: ASTM C591, Type 1 or 2, foamed-in-place or in board form, with an oxygen index of not less than 22 percent when tested in accordance with ASTM D2863; or
b. Rigid Polystyrene Foam Board: ASTM C578, Type I or II.
2.4 STANDARD STEEL FRAMES: HMMA Guide Specification shall match door as specified. Form frames to sizes and shapes indicated, with welded corners or knock-down field-assembled corners. Provide steel frames for doors unless otherwise indicated.
2.4.1 Welded Frames: Continuously weld frame faces at corner joints. Mechanically interlock or continuously weld stops and rabbets. Grind welds smooth.
2.4.2 Knock-Down Frames: Design corners for simple field assembly by concealed tenons, splice plates, or interlocking joints that produce square, rigid corners and a tight fit and maintain the alignment of adjoining members. Provide locknuts for bolted connections.
6.19 08110-4 394.107.001 SECTION 08110
STEEL DOORS AND FRAMES
2.4.3 Stops and Beads: Form stops and beads from 20-gauge steel. Provide for glazed and other openings in standard steel frames. Secure beads to frames with oval-head, countersunk Phillips-head self-tapping sheet metal screws or concealed clips and fasteners. Space fasteners approximately 12 to 16 inches on centers. Miter molded shapes at corners. Butt or miter square or rectangular beads at corners.
2.4.4 Terminated Stops: Where indicated, terminate interior door frame stops 6 inches above floor. Do not terminate stops of frames for lightproof, soundproof, or lead-lined doors.
2.4.5 Cased Openings: Fabricate frames for cased openings of same material, gauge, and assembly as specified for metal door frames, except omit door stops and preparation for hardware.
2.4.6 Anchors: Provide anchors to secure the frame to adjoining construction. Provide steel anchors, zinc-coated or painted with rust-inhibitive paint, not lighter than 18 gauge.
2.4.6.1 Wall Anchors: Provide a minimum of three anchors for each jamb. Locate anchors opposite top and bottom hinges and midway between.
a. Masonry: Provide anchors of corrugated or perforated steel straps or 3/16-inch diameter steel wire, adjustable or T-shaped;
b. Stud Partitions: Weld or otherwise securely fasten anchors to backs of frames. Design anchors to be fastened to wood studs with nails, to closed steel studs with sheet metal screws, and to open steel studs by wiring or welding;
c. Completed Openings: Secure frames to previously placed concrete or masonry with expansion bolts in accordance with SDI 111F; and
2.4.6.2 Floor Anchors: Provide floor anchors drilled for 3/8-inch anchor bolts at bottom of each jamb member. Where floor fill occurs, terminate bottom of frames at the indicated finished floor levels and support by adjustable extension clips resting on and anchored to the structural slabs.
2.5 WEATHERSTRIPPING: As specified in Section 08710, "Finish Hardware".
2.5.1 Integral Gasket: Black synthetic rubber gasket with tabs for factory fitting into factory slotted frames, or extruded neoprene foam gasket made to fit into a continuous groove formed in
6.19 08110-5 394.107.001 SECTION 08110
STEEL DOORS AND FRAMES
the frame, may be provided in lieu of head and jamb seals specified in Section 08710, "Finish Hardware". Insert gasket in groove after frame is finish painted.
2.6 HARDWARE PREPARATION: Reinforce, drill, and tap doors and frames to receive finish hardware. Prepare doors and frames for hardware in accordance with the applicable requirements of SDI 107 and DHI A115.1, DHI A115.2, DHI A115.4, DHI A115.5, DHI A115.7, DHI A115.12, DHI A115.13, DHI A115.14. Drill and tap for surface-applied hardware at the project site. Build additional reinforcing for surface-applied hardware into the door at the factory. Locate hardware in accordance with the requirements of SDI 100, as applicable. Punch door frames, with the exception of frames that will have weatherstripping to receive a minimum of two rubber or vinyl door silencers on lock side of single doors and one silencer for each leaf at heads of double doors. Set lock strikes out to provide clearance for silencers.
2.7 FINISHES:
2.7.1 Hot-Dip Zinc-Coated and Factory-Primed Finish: Fabricate doors and frames from galvanized steel, ASTM A526, Coating Designation G60 or A60 (galvannealed). Repair damaged zinc-coated surfaces by the application of zinc dust paint conforming to DOD-P-21035. Phosphate treat and factory prime zinc-coated surfaces as specified in SDI 100. Provide for all exterior doors.
2.8 FABRICATION AND WORKMANSHIP: Finished doors and frames shall be strong and rigid, neat in appearance, and free from defects, waves, scratches, cuts, dents, ridges, holes, warp, and buckle. Molded members shall be clean cut, straight, and true, with joints coped or mitered, well formed, and in true alignment. Dress exposed welded and soldered joints smooth. Design door frame sections for use with the wall construction indicated. Corner joints shall be well formed and in true alignment. Conceal fastenings where practicable. On wraparound frames for masonry partitions, provide a throat opening 1/8 inch larger than the actual masonry thickness. Design other frames in exposed masonry walls or partitions to allow sufficient space between the inside back of trim and masonry to receive caulking compound.
2.8.1 Grouted Frames: For frames to be installed in exterior walls and to be filled with mortar or grout, fill the stops with strips of rigid insulation to keep the grout out of the stops and to facilitate installation of stop-applied head and jamb seals.
6.19 08110-6 394.107.001 SECTION 08110
STEEL DOORS AND FRAMES
PART 3 - EXECUTION
3.1 INSTALLATION:
3.1.1 Frames: Set frames in accordance with HMMA Guide Specifications. Plumb, align, and brace securely until permanent anchors are set. Anchor bottoms of frames with expansion bolts or powder-actuated fasteners. Build in or secure wall anchors to adjoining construction. Where frames require ceiling struts or overhead bracing, anchor frames to the struts or bracing. Backfill frames with mortar. When an additive is provided in the mortar, coat inside of frames with corrosion-inhibiting bituminous material. For frames in exterior walls, assure that stops are filled with rigid insulation before grout is placed.
3.1.2 Doors: Hang doors in accordance with clearances specified in HMMA Guide Specifications. After erection and glazing, clean and adjust hardware.
3.2 PROTECTION: Protect doors and frames from damage. Repair damaged doors and frames prior to completion and acceptance of the project or replace with new, as directed. Wire brush rusted frames until all rust is removed, clean thoroughly, and apply an all-over coat of rust-inhibitive paint of the same type used for shop coat.
3.3 CLEANING: Upon completion, clean exposed surfaces of doors and frames thoroughly. Remove mastic smears and other unsightly marks.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - STEEL DOORS AND FRAMES:
4.1.1 Measurement for Steel Doors and Frames shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - STEEL DOORS AND FRAMES:
4.2.1 For Steel Doors and Frames, not included in other unit or lump sum price items, payment for Steel Doors and Frames will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 08110-7 394.107.001 SECTION 08360
SECTIONAL OVERHEAD DOORS
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Sectional Overhead Doors, as shown on the Plans, as specified, and/or directed.
1.1.2 For electrically operated overhead doors, Contract No. 2A to furnish and install doors, tracks, hardware, door and operator support brackets/systems, door operators, door controllers, safeties and all control components. Contract No. 2C to provide all interconnecting power and control conductors and conduit.
1.1.3 For electrically operated overhead doors, Contract No. 2A to coordinate with Contract No. 2C and provide information on motor operator location, voltage, number phases, amps, etc. prior to Contract No. 2C panelboard shop drawing submission.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American Society for Testing and Materials (ASTM) Publications:
A36/A36M Structural Steel
A227 Steel Wire, Cold-Drawn for Mechanical Springs
A229 Steel Wire, Oil-Tempered for Mechanical Springs
A386 Zinc Coating (Hot-Dip) on Assembled Steel Products
A525 General Requirements for Steel Sheet, Zinc-Coated (Galvanized) by the Hot-Dip Process
B209/B209M Aluminum and Aluminum-Alloy Sheet and Plate
B221/B221M Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Shapes, and Tubes
6.19 08360-1 394.107.001 SECTION 08360
SECTIONAL OVERHEAD DOORS
E330 Structural Performance of Exterior Windows, Curtain Walls, and Doors By Uniform Static Air Pressure Difference
1.2.2 Military Specification (MIL):
DOD-P-21035 Paint, High Zinc Dust Content, Galvanizing Repair (Metric)
1.2.3 National Association of Architectural Metal Manufacturers (NAAMM) Publication:
MFM Metal Finishes Manual (Finish Designation)
1.2.4 National Association of Garage Door Manufacturers (NAGDM) Publication:
A216.1 Specifications for Sectional Overhead Type Doors
1.2.5 National Electrical Manufacturers Association (NEMA) Publications:
ICS1 General Standards for Industrial Control and Systems
ICS2 Industrial Control Devices, Controllers and Assemblies
ICS6 Enclosures for Industrial Controls and Systems
MG1 Motors and Generators
ST20 Dry-Type Transformers for General Applications
1.2.6 National Fire Protection Association (NFPA) Publication:
70 National Electrical Code
1.3 SUBMITTALS: Submit the following.
1.3.1 Manufacturer's Catalog Data:
a. Sectional overhead doors
6.19 08360-2 394.107.001 SECTION 08360
SECTIONAL OVERHEAD DOORS
b. Motor and controls
For electrically motor-operated doors, submit manufacturer's wiring diagrams for motor and controls.
1.3.2 Drawings:
a. Sectional overhead doors
Show types, sizes, locations, metal gauges, hardware provisions, installation details, and other details of construction. For electrically-operated doors (Doors numbered 100), include supporting brackets for motors, location, type, and ratings of motors, switches, and safety devices.
1.4 DELIVERY AND STORAGE: Protect doors and accessories from damage during delivery, storage, and handling. Clearly mark manufacturer's brand name. Store doors in dry locations with adequate ventilation, free from dust and water. Storage shall permit easy access for inspection and handling. Remove damaged items and provide new.
PART 2 - PRODUCTS
2.1 MATERIALS:
2.1.1 Hard-Drawn Springwire: ASTM A227.
2.1.2 Oil-Tempered Springwire: ASTM A229.
2.1.3 Steel Sheet: ASTM A525.
2.1.4 Steel Shapes: ASTM A36/A36M.
2.1.5 Aluminum Extrusions: ASTM B221/B221M, Alloy 6063-T5.
2.1.6 Aluminum Sheets and Strips: ASTM B209/B209M, alloy and temper best suited for the purpose.
2.1.7 Glass: Fully tempered, clear float glass 1/8 inch thick.
6.19 08360-3 394.107.001 SECTION 08360
SECTIONAL OVERHEAD DOORS
2.2 DOORS: NAGDM A216.1 Commercial door, except as specified otherwise. Metal doors shall be horizontal sections hinged together which operate in a system of tracks to completely close the door opening in the closed position and make the full width and height of the door opening available for use in the open position. Provide a permanent label on the door indicating the name and address of the manufacturer. Doors shall be of the standard lift type designed to slide up and back into a horizontal overhead position and requiring a maximum of 16 inches of headroom for 2-inch tracks and 21 inches of headroom for 3-inch tracks. Doors shall be operated by hand chain with gear or sprocket reduction, and by electric power with auxiliary hand chain operation (Doors numbered 100).
2.3 DESIGN REQUIREMENTS: NAGDM A216.1. Doors shall remain operable and undamaged after conclusion of tests conducted in accordance with ASTM E330 using the design wind load.
2.4 FABRICATION:
2.4.1 Steel Overhead Doors: Door sections shall be formed of hot-dipped galvanized steel not lighter than 16 gauge with flush surface without ribs or grooves or 20 gauge with longitudinal integral reinforcing ribs or 24 gauge with longitudinal integral reinforcing ribs and flat bottom V-grooves. Sections shall be not less than 2 inches in thickness. Meeting rails shall have interlocking joints to ensure a weathertight closure and alignment for full width of the door. Sections shall be of the height indicated or the manufacturer's standard, except the height of an intermediate section shall not exceed 24 inches. Bottom sections may be varied to suit door height, but shall not exceed 30 inches in height. Provide glass panels as indicated. Install panels using rubber gaskets as standard with the door manufacturer.
2.4.1.1 Insulated Sections: Door sections shall be insulated with fibrous glass or plastic foam to provide a "R" factor of 4.75 or more. Interior of door sections shall be covered with steel sheets of not lighter than 24 gauge to completely enclose the insulating material.
2.4.2 Tracks: Provide galvanized steel tracks not lighter than 13 gauge for 2-inch tracks and not lighter than 11 gauge for 3-inch tracks. Provide vertical tracks with continuous steel angle not lighter than 13 gauge for installation to walls. Vertical track shall be inclined through use of adjustable brackets to obtain a weathertight closure at jambs. Horizontal track shall be reinforced with galvanized steel angle; support from track ceiling construction with galvanized steel angle with cross bracing, as required, to provide a rigid installation.
6.19 08360-4 394.107.001 SECTION 08360
SECTIONAL OVERHEAD DOORS
2.4.3 Hardware: Provide hinges, brackets, rollers, locking devices, and other hardware required for complete installation. Roller brackets and hinges shall be 13 gauge galvanized steel. Rollers shall have ball bearings and case-hardened races. Provide reinforcing on doors where roller hinges are connected. Provide a positive locking device and cylinder lock with two keys on manually operated doors.
2.4.4 Counterbalancing: Doors shall be counterbalanced by means of an oil-tempered, helical-wound torsional spring mounted on a steel shaft. Spring tension shall be adjustable; connect spring to doors with cable with a safety factor of at least 7 to 1. The force required to operate manual pushup doors shall not exceed 25 pounds. The force required to operate manual chain hoist doors shall not exceed 35 pounds.
2.5 MANUAL OPERATORS:
2.5.1 Pushup Operators: Provide lifting handles on both sides of door. The force required to operate the door shall not exceed 25 pounds. Provide pulldown straps or ropes at bottom of doors over 7 feet high.
2.5.2 Chain Hoist Operators: Provide a galvanized, endless chain operating over a sprocket. Extend chain to within 4 feet of the floor and mount on inside of building. Obtain reduction by use of roller chain and sprocket drive or gearing. Provide chain cleat and pin for securing operator chain. Hoist shall allow for future installation of power operators. The force required to operate the door shall not exceed 35 pounds.
2.6 ELECTRIC OPERATORS (DOORS NUMBERED 100):
2.6.1 Operator Features: Provide operators of the drawbar type or side mount (jack shaft) type as recommended by the manufacturer. Operators shall include electric motor, machine-cut reduction gears, steel chain and sprockets, magnetic brake, brackets, push button controls, limit switches, magnetic reversing contactor, a manual chain hoist operator as specified above for emergency use, and other accessories necessary for operation. The electric operator shall be designed so that the motor may be removed without disturbing the limit switch timing and without affecting the manual operator. Provide the operator with slipping clutch coupling to prevent stalling the motor. The emergency manual operator shall be clutch controlled so that it may be engaged and disengaged from the floor; operation shall not affect limit switch timing. The manual operator is not required if door can be manual-pushup operated with a force not to exceed 25 pounds. Provide an electrical or mechanical device that disconnects the motor from the operating mechanism when the manual operator is engaged.
6.19 08360-5 394.107.001 SECTION 08360
SECTIONAL OVERHEAD DOORS
2.6.2 Motors: NEMA MG1, high-starting torque, reversible type with sufficient horsepower and torque output to move the door in either direction from any position. Motor shall produce a door travel speed of not less than two-thirds foot or more than one foot per second without exceeding the rated two-thirds foot or more than one foot per second without exceeding the rated capacity. Motors shall operate on current of the characteristics indicated at not more than 3600 rpm. Motors shall be 480V, 3 phase.
2.6.3 Controls: Each door motor shall have an enclosed, across-the-line type, magnetic reversing contactor, thermal overload and under voltage protection, solenoid-operated brake, limit switches, and control switches. Locate control switches at least 5 feet above the floor so the operator will have complete visibility of the door at all times. Control equipment shall conform to NEMA ICS1 and NEMA ICS2. Control enclosures shall be NEMA ICS6, Type 12 or Type 4, except that contactor enclosures may be Type 1. Each control switch station shall be of the three-button type; buttons shall be marked "OPEN", "CLOSE", and "STOP". The "OPEN" and "STOP" buttons shall require only momentary pressure to operate. The "CLOSE" button shall require constant pressure to maintain the closing motion of the door. If the door is in motion and the "STOP" button is pressed or the "CLOSE" button released, the door shall stop instantly and remain in the stop position; from the stop position, the door may be operated in either direction by the "OPEN" or "CLOSE" buttons. Push buttons shall be full-guarded to prevent accidental operation. Provide limit switches to automatically stop doors at the fully open and closed positions. Limit switch positions shall be readily adjustable.
2.6.4 Safety Device: Provide a safety device on the bottom edge of electrically-operated doors. The device shall immediately stop and reverse the door in the closing travel upon contact with an obstruction in the door opening or upon failure of the device of any component of the control system and cause the door to return to the full open position. The door-closing circuit shall be automatically locked out, and the door shall be operable manually until the failure or damage has been corrected. Do not use the safety device as a limit switch.
2.6.5 Control Transformers: NEMA ST20. Provide control power transformers internal to door controller as necessary to reduce the voltage on the control circuits to 120 volts or less.
2.6.6 Electrical Components: NFPA 70. The door manufacturer shall furnish manual or automatic control and safety devices, including extra flexible Type SO cable and spring-loaded automatic takeup reel or equivalent device, as required for operation of the doors.
2.7 WEATHER SEALS AND SAFETY DEVICE: Provide exterior doors with weatherproof joints between sections by means of tongue-and-groove joints, rabbeted joints, shiplap joints, or wool pile, vinyl or rubber weatherstripping; a rubber, wool pile, or vinyl, adjustable weatherstrip
6.19 08360-6 394.107.001 SECTION 08360
SECTIONAL OVERHEAD DOORS
at the top and jambs; and a compressible neoprene, rubber, wool pile, or vinyl weather seal attached to the bottom of the door. On exterior doors that are electrically operated (Doors numbered 100) the bottom seal shall be combination compressible weather seal and safety device for stopping the travel of the door.
2.8 FINISHES: Concealed ferrous metal surfaces and tracks shall be hot-dip galvanized. Other ferrous metal surfaces, except rollers, shall be hot-dip galvanized and shop primed.
2.8.1 Galvanized and Shop-Primed: Surfaces specified shall have a zinc coating, a phosphate treatment, and a shop prime coat of rust-inhibitive paint. The galvanized coating shall conform to ASTM A525, coating designation G90, for steel sheets, and ASTM A386 for assembled steel products. The weight of coatings for assembled products shall be as designated in Table I of ASTM A386 for the class of material to be coated. The prime coat shall be a type especially developed for materials treated by phosphates and adapted to application by dipping or spraying. Repair damaged zinc-coated surfaces by the application of galvanizing repair paint conforming to DOD-P-21035 and spot prime. At the Contractor's option, a two-part system including bonderizing, baked-on epoxy primer, and baked-on enamel topcoat may be applied in lieu of prime coat specified.
PART 3 - EXECUTION
3.1 INSTALLATION: NFPA 70. Install doors in accordance with approved shop drawings and manufacturer's instructions. Accurately locate anchors and inserts for guides, brackets, motors, switches, hardware, and other accessories. Upon completion, doors shall be weathertight and free from warp, twist, or distortion. Doors shall be lubricated and adjusted to operate freely.
3.2 ELECTRICAL WORK: NFPA 70.
3.3 TESTING: After installation is complete, operate doors to demonstrate installation and function of operators, safety features, and controls. Correct deficiencies.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - SECTIONAL OVERHEAD DOORS:
4.1.1 Measurement for Sectional Overhead Doors shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
6.19 08360-7 394.107.001 SECTION 08360
SECTIONAL OVERHEAD DOORS
4.2 PAYMENT - SECTIONAL OVERHEAD DOORS:
4.2.1 For Sectional Overhead Doors, not included under other unit or lump sum price items, payment for Sectional Overhead Doors will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 08360-8 394.107.001 SECTION 08511
STEEL WINDOWS
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials, and equipment for Steel Windows (Fixed Lite), as shown on the Plans, as specified, and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American Society for Testing and Materials (ASTM) Publications:
A569 Steel, Carbon (0.15 Maximum, Percent), Hot- Rolled Sheet and Strip Commercial Quality
A653 Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process
B633 Electrodeposited Coatings of Zinc on Iron and Steel
B766 Electrodeposited Coatings of Cadmium
E163 Fire tests of Window Assemblies
E283 Determining the Rate of Air Leakage Through Exterior Windows, Curtain Walls, and Doors Under Specific Pressure Differences Across the Specimen
E330 Structural Performance of Exterior Windows, Curtain Walls, and Doors by Uniform Static Air Pressure Difference
E547 Water Penetration of Exterior Windows, Curtain Walls, and Doors by Cyclic Static Air Pressure Differential
6.19 08510-1 394.107.001 SECTION 08511
STEEL WINDOWS
1.2.2 American Society of Mechanical Engineers (ASME) Publications:
B18.6.3 Machine Screws and Machine Screw Nuts
B18.6.4 Thread Forming and Thread Cutting Tapping Screws and Metallic Drive Screws (Inch Series)
1.2.3 National Fire Protection Association (NFPA) Publications:
101 Safety to Life from Fire in Buildings and Structures
1.3 PERFORMANCE REQUIREMENTS:
1.3.1 Steel windows shall conform to the voluntary specifications in AAMA/NWWDA 101/I.S.2-97 and be designed to meet the following performance requirements.
1.3.1.1 Air Infiltration: Air infiltration shall not exceed .3 SCFM per square foot of window area at a static air pressure difference of 1.57 PSF as established by AAMA/NWWDA 101/I.S.2- 97 when tested in accordance with ASTM E 283.
1.3.1.2 Water Resistance: When tested in accordance with ASTM E 547, there shall be no water leakage at a static air pressure difference of 6 PSF.
1.3.2 Life Safety Criteria: Windows shall conform to NFPA 101 Life Safety Code when rescue and/or second means of escape are indicated.
1.4 SUBMITTALS:
1.4.1 Manufacturer’s descriptive data and catalog cut sheets.
1.4.2 Drawings indicating elevations of windows, rough-opening dimensions for each type and size of windows, section details, fastenings, methods of installation and anchorage, connections with other work, type of wall construction, method of glazing, types and locations of operating hardware, mullion details, weather-stripping details, screen details, and window schedules showing locations of each window type and indicting compliance with fire safety code, where required.
1.4.3 Manufacturer’s preprinted installation instructions and cleaning instructions.
1.4.4 Manufacturer’s standard color samples of painted finishes.
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1.5 DELIVERY, STORAGE AND HANDLING:
1.5.1 Delivery: Protect windows and accessories from damage during delivery, storage, and handling. Clearly mark manufacturer’s brand name. Store windows in dry locations with adequate ventilation, free from dust and water, and in such a manner as to permit access for inspection and handling. Handle windows carefully to prevent damage. Remove damaged items that cannot be restored to like-new condition and provide new items.
PART 2 - PRODUCTS
2.1 STEEL WINDOW TYPES:
2.1.1 Projected steel windows shall be designed for inside field glazing, and for glass types scheduled on drawings or otherwise specified. Units shall be complete with glass and glazing provisions to meet requirements of paragraph WINDOW PERFORMANCE. Glazing material shall be compatible with steel, and shall not require painting.
2.2 MATERIALS:
2.2.1 Steel Frames and Inserts:
2.2.1.1 Steel frames shall be fabricated from roll-formed galvanized lock-forming quality steel per ASTM A653.
2.2.1.2 Frame corners shall mitered and welded. Integral muntins where required shall be galvanized roll-formed material fitted and welded.
2.2.1.3 Operable insert/sash shall be supported on two heavy-duty stainless steel four-bar hinges.
2.2.2 Installation Kits:
2.2.2.1 Provide attachable fin installation kits for all windows.
2.2.2.2 Provide subframe installation kits for all windows.
2.2.3 Weather Stripping:
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2.2.3.1 The insert will accommodate double weather-stripping around the entire perimeter of the insert. Weather-stripping for the insert shall be designed to meet water penetration and air infiltration requirements specified under paragraph WINDOW PERFORMANCE, and shall be manufactured of material compatible with steel and resistant to weather. Weather-strips shall be factory applied and easily replaced in the field.
2.2.4 Formed Component Parts:
2.2.4.1 Formed component parts shall be hot-rolled sheet steel conforming to ASTM A569, commercial quality with a minimum of 0.15 percent carbon.
2.2.4.2 Sheet steel shall be zinc coated (galvanized) by the hot-dip process in accordance with ASTM A653 or ASTM A924.
2.2.5 Screws and Bolts: Screws and bolts shall conform to ASTM B766, ASME B18,6.3 and ASME B18.6.4.
2.2.6 Fasteners: Fastening devices shall be window manufacturer’s design made from non- magnetic stainless steel, cadmium-plated steel, zinc-plated steel, nickel/chrome-plated steel or magnetic stainless steel.
2.2.7 Window Anchors: Anchors for installing windows shall be stainless steel or hot-dip zinc coated steel conforming to ASTM A123.
2.2.8 Glass and Glazing:
2.2.8.1 Insulated glass unit
PART 3 - EXECUTION
3.1 FABRICATION:
3.1.1 Fabricate windows in accordance with approved shop drawings.
3.1.2 Frame sections shall be one piece sections with corners mitered, welded and dressed smooth.
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3.1.3 Required muntins shall be securely welded to the frame members and at all intersections.
3.1.4 All windows shall be designed for inside glazing.
3.1.5 All windows shall be factory glazed with UL labeled glass meeting or exceeding the hourly rating required for the frame label. Individual lites shall display a UL label permanently affixed and in accordance with the requirements o the International Building Code and NFPA 80.
3.2 FINISHES:
3.2.1 Prime Coat: Steel windows, fins, mullions, cover plates and associated parts shall be cleaned, pretreated with iron phosphate and factory painted manufacturer’s standard primer coat in a dry film thickness of not less than 0.025 mm (1.0 mil).
3.2.2 Finish Coat - Manufacturer’s Standard Color: Steel windows, fins, mullions, cover plates and associated parts shall be cleaned, pretreated with iron phosphate and factory powder coated and cured with a manufacturer’s standard color in a dry film thickness of not less than 0.050 mm (2.0 mil).
3.2.3 Finish Coat - Specified Color Match: Steel windows, fins, mullions, cover plates and associated parts shall be cleaned, pretreated with iron phosphate and factory coated with baked alkyd enamel with a manufacturer’s standard color in a dry film thickness of not less than 0.050 mm (2.0 mil).
3.3 EXAMINATION:
3.3.1 Window openings shall conform to details and dimensions shown on the approved shop drawings.
3.3.2 Notify the Engineer immediately of conditions that may adversely affect the window installation. Correct conditions prior to installing windows.
3.4 INSTALLATION:
3.4.1 Steel windows shall be installed in accordance with approved shop drawings and manufacturer’s approved recommendations.
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3.4.2 Steel surfaces in close proximity with masonry, concrete, wood, and dissimilar metals other than stainless steel, zinc, cadmium, or small areas of white bronze shall be protected from direct contact.
3.4.3 Verify that weep features at the bottom of the sills are opened at least 1/8” x 1”. Failure to do so may lead to premature finish failures.
3.4.4 The completed window installation shall be watertight.
3.5 ADJUSTING AND CLEANING:
3.5.1 Steel window finish and glass shall be cleaned on interior and exterior sides in accordance with window manufacturer’s recommendation. Alkaline, abrasive or brick wash agents shall not be used.
3.5.2 Operable sash shall be adjusted per manufacturer’s instruction to provide minimal operating force.
3.6 PROTECTION:
3.6.1 Protect installed products and finished surfaces from damage during construction.
3.6.2 Touch-up any abraded surface of the window finish with air dry paint furnished by the window manufacturer.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT – STEEL WINDOWS:
4.1.1 Measurement for Steel Windows shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT – STEEL WINDOWS:
4.2.1 For Steel Windows, not included in other unit or lump sum price items, payment for Steel Windows will be made at the applicable price stated in the Bid.
END OF SECTION
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PART 1 GENERAL
1.1 SUMMARY
A. Section Includes:
1. Finish hardware for doors as specified and as listed in "Hardware Groups" and required by actual conditions.
2. Include screws, special screws, bolts, special bolts, expansion shields, and other devices for proper application of hardware.
B. Related Sections:
1. Section 06100: Rough Carpentry 2. Section 08110: Steel Doors and Frames
1.2 GENERAL REQUIREMENTS A. Provide items, articles, materials, operations and methods listed, mentioned or scheduled herein or on drawings, in quantities as required to complete project. Provide hardware that functions properly. Prior to furnishing hardware, advise Architect of items that will not operate properly, are improper for conditions, or will not remain permanently anchored.
1.3 SUBMITTALS A. Hardware Schedule: Submit 5 copies of hardware schedule in vertical format as illustrated by the Sequence of Format for the Hardware Schedule as published by the Door and Hardware Institute. Schedules, which do not comply, will be returned for correction before checking. Hardware schedule shall clearly indicate architect's hardware group and manufacturer of each item proposed. A certified Architectural Hardware Consultant, who shall affix his or her seal attesting to the completeness and correctness of the schedule, shall review the schedule prior to submission.
1. Provide 2 copies of illustrations from manufacturer’s catalogs and data in brochure form. 2. Check specified hardware for suitability and adaptability to details and surrounding conditions. Indicate unsuitable or incompatible items and proposed substitutions in hardware schedule. 3. Provide listing of manufacturer's template numbers for each item of hardware in hardware schedule.
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4. Furnish other Contractors and Subcontractors concerned with copies of final approved hardware schedule. Submit necessary templates and schedules as soon as possible to hollow metal, wood door, and aluminum door fabricators in accordance with schedule they require for fabrication. 5. Samples: Lever design or finish sample: Provide 3 samples if requested by architect.
B. Wiring Diagrams: Provide complete and detailed system operation and elevation diagrams specially developed for each opening requiring electrified hardware, except openings where only magnetic hold-opens or door position switches are specified. Provide these diagrams with hardware schedule submittal for approval. Provide detailed wiring diagrams with hardware delivery to jobsite.
C. Installation Instructions: Provide manufacturer's written installation and adjustment instructions for finish hardware. Send installation instructions to site with hardware. D. Templates: Submit templates and "reviewed Hardware Schedule" to door and frame supplier and others as applicable to enable proper and accurate sizing and locations of cutouts and reinforcing. E. Contract Closeout Submittals: Comply with Section 01700 including specific requirements indicated.
1. Operating and maintenance manuals: Submit 3 sets containing the following: a. Complete information in care, maintenance, and adjustment, and data on repair and replacement parts, and information on preservation of finishes. b. Catalog pages for each product. c. Name, address, and phone number of local representative for each manufacturer. d. Parts list for each product. 2. Copy of final approved hardware schedule, edited to reflect, "As installed". 3. Copy of final keying schedule. 4. As installed "Wiring Diagrams" for each opening connected to power, both low voltage and 110 volts. 5. One complete set of special tools required for maintenance and adjustment of hardware, including changing of cylinders.
1.4 QUALITY ASSURANCE A. Manufacturer: Obtain each type of hardware (i.e., latch and locksets, hinges, closers) from single manufacturer, although several may be indicated as offering products complying with requirements.
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B. Supplier: Recognized architectural finish hardware supplier, with warehousing facilities, who has been providing hardware for period of not less than 3 years. The supplier shall be, or employ, a certified Architectural Hardware Consultant (AHC), who is registered in the continuing education program as administered by the Door and Hardware Institute. The hardware schedule shall be prepared and signed by a certified AHC. C. Installer: Firm with 3 years experience in installation of similar hardware to that required for this project, including specific requirements indicated. D. Regulatory Label Requirements: Provide nationally recognized testing agency label or stamp on hardware for labeled openings. Where UL requirements conflict with drawings or specifications, hardware conforming to UL requirements shall be provided. Conflicts and proposed substitutions shall be clearly indicated in hardware schedule. E. Handicapped Requirements: Doors to stairs (other than exit stairs), loading platforms, boiler rooms, stages and doors serving other hazardous locations shall have knurled or other similar approved marking of door lever handles or cross bars in accordance with local building codes. F. Pre-Installation Conference: Prior to the installation of hardware, manufacturer's representatives for locksets, closers, and exit devices shall arrange and hold a jobsite meeting to instruct the installing contractor's personnel on the proper installation of their respective products. A letter of compliance, indicating when this meeting is held and who is in attendance, shall be sent to the Architect and Owner.
1.5 DELIVERY, STORAGE AND HANDLING A. Deliver hardware to jobsite in manufacturer's original packaging, marked to correspond with approved hardware schedule. Do not deliver hardware until suitable locked storage space is available. Check hardware against reviewed hardware schedule. Store hardware to protect against loss, theft or damage. B. Deliver hardware required to be installed during fabrication of hollow metal, aluminum, wood, or stainless steel doors prepaid to manufacturer.
1.6 ELECTRICAL HARDWARE
A. Electrical hardware to be installed by the Contractor in accordance with manufacturer’s instructions, neatly fitted, properly adjusted to operate as intended and left free of defects.
B. Prior to installation, the hardware supplier shall confer with the Contractor and Electrical Contractor/Subcontractor at the job site to review proper installation, application, location
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and adjustment of the finish hardware. Coordinate automatic door operator and security systems or other system requirements where applicable.
C. Installation:
1. The Electrical Contractor/Subcontractor will furnish and install all required electrical service, conduit, mortar guards, wiring, junction boxes, and connect hardware items to the building’s power source, fire alarm and security systems in cooperation with the hardware installer. 2. All remote security control or fire alarm panels will be furnished and installed by the Electrical Contractor/Subcontractor. 3. Hardware suppliers to provide door and frame fabricators, all templates required for the preparation of doors and frames to receive electrical hardware items. 4. Hardware supplier to furnish product information, wiring diagrams and electrical data to the Electrical Contractor/Subcontractor 5. See Contract Documents for electrical work to determine power provided for electrical hardware and verify information prior to furnishing hardware. 6. Instruction of Owner: On completion of the project, the hardware supplier shall instruct the Owners representative as to proper operation, adjustment and maintenance of electrical hardware. Any hardware function or feature not readily apparent shall be described at this time.
1.7 WARRANTY A. Guarantee workmanship and material provided against defective manufacture. Repair or replace defective workmanship and material appearing within period of one year after Substantial Completion. B. Provide ten-year factory warranty on door closer body against defects in material and workmanship from date of occupancy of Project. C. Replace shortages and incorrect items with correct material at no additional cost to Owner. D. At completion of project, qualified factory representative shall inspect closer installations. After this inspection, letter shall be sent to Architect reporting on conditions, verifying that closers have been properly installed and adjusted.
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PART 2 PRODUCTS
2.1 BUTTS AND HINGES A. Acceptable Manufacturers and Types: Type McKinney Stanley 2 TA2714 FBB179 3 TA2314 FBB191 4 T4A3786 FBB168 5 T4A3386 FBB199
B. Application: 1. Exterior out-swinging doors Type 5 x NRP 2. Exterior in-swinging doors and vestibule doors Type 4 3. Interior doors with closers Type 2 or 4 4. Interior Bathroom doors Type 3 or 5 US32D 4. Interior doors over 36 inches wide Type 4 5. Interior doors 36 inches or less Type 2 6. Provide NRP (non-removable pins) at out-swinging lockable doors. C. Size: 1. 2-1/4 inch Doors 5 inch by 5 inch 2. 1-3/4 inch Doors 4-1/2 inch by 4-1/2 inch 3. 1-3/8 inch Doors 3-1/3 inch by 3-1/2 inch D. Quantity: 1. 2 - hinges per leaf for openings through 60 inches high. 2. 1 - additional hinge per leaf for each additional 30 inches in height or fraction thereof. 3. 4 - Dutch doors up to 90 inches in height. E. Drill 5/32-inch hole and use No. 12, 1-1/4 inch steel threaded to the head wood screws for hinges on wood doors. F. Finish as defined under Section 2.21
2.2 CONTINUOUS HINGES A. Acceptable manufacturers: McKinney Markar Roton MCK-12HD FM-2000 780-112HD MCK-25HD FM-2011 780-224HD
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B. Provide one of the above two models of continuous hinges as appropriate for the type, inset, and thickness of door where specified. Coordinate hinge types with the door supplier. C. Finish as defined under Section 2.21.
2.3 FLUSH BOLTS AND DUSTPROOF STRIKES A. Acceptable manufacturers: Rockwood Ives Glynn-Johnson 557 358 FB6W 555 458 FB6 1842 559 FB7 1942 556 FB8 570 489 x 487 DP2
B. Labeled or Non-labeled Openings: Provide 2 flush bolts 555 or 557, as applicable, for inactive leaf of pairs of locked and latched doors. Locate centerline of top bolt not more than 78 inches from finished floor. C. Labeled Egress Openings: Provide automatic flush bolt set 1842 or 1942, as applicable, for inactive leaf of pairs of doors. D. Provide dustproof strike 570 for all bottom bolts. E. Finish as defined under Section 2.21
2.4 LOCKSETS – MORTISE
A. All locks to be heavy duty commercial mortise type and meet these certifications: ANSI A156.13 Grade 1, Operational and Security.
1. 12 Gauge steel cap and case for all functions 2. One-piece ¾-inch, stainless steel, anti-friction latchbolts. 3. One inch, stainless steel deadbolt with hardened steel roller inserts 4. Hand of lock is to be easily field reversible without opening the lock body case. 5. All lever trim shall be thru-bolted through the door and the lock case. 6. All cylinder collars are to be cast.
B. Provide manufacturer’s standard wrought box strike for each latch or lock bolt, with curved lip extended to protect frame, finished to match hardware set.
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C. Provide removable cores and substitute BEST cores to meet Owner’s requirements.
D. Manufacturers: Provide one the following:
Sargent Corbin Russwin Trim LNL NSA ANSI Functions Numbers F01 Passage 8215 ML2010 F22 Privacy 8265 ML2060 F05 Classroom 8237 ML2055 F07 Storeroom 8204 ML2057 F04 Entrance 8205 ML2051 F13 Dormitory 8225 ML2065
2.5 LOCKSETS – CYLINDRICAL A. Acceptable Manufacturer and Series: Sargent Corbin Best 93k Series Russwin Trim LL NZD #14 ANSI Function Function Numbers F75 Passage 10U15 CL3310 N F76 Privacy 10U65 CL3320 L F84 Classroom 10G37 CL3355 R F86 Storeroom 10G04 CL3357 D F81 Entrance 10G05 CL3351 AB F80 Communicating 10G30 CL3362 N
B. Locksets shall have 2-3/4” backset, standard C. Provide manufacturer’s standard wrought box strike for each latch or lock bolt, with curved lip extended to protect frame, finished to match hardware set. D. Locksets shall be thru-bolted thru the door separate from the ANSI 161 prep. E. Locksets shall have a five year limited mechanical warranty. F. Locksets shall exceed ANSI 156.2 Grade 1 Standards 6.19 08710 - 7 394.107.001 SECTION 08710
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G. Locksets shall be meet ADA requirements. H. Finish as defined under section 2.21 2.6 CYLINDERS AND KEYING (BEST System) A. Provide locks and exit devices requiring cylinders with 6-pin cylinders, which comply with performance requirements of ANSI A156.5. All keys to be of nickel silver only. B. Furnish all locks and cylinders keyed to the existing Best Core key system. All keying to be accomplished at the factory of the lock manufacturer. C. Each cylinder or lock to be supplied with three- (3) change keys. D. Six (6) master keys to be supplied for each master key group. E. All cylinders and keys shall be properly tagged to indicate their intended location and to enable the Owner, with a minimum of effort, to establish his key control system. F. Construction keying to be used on this project. G. Stamp all change keys with key symbol (VKC), but do not stamp with key section or bitting number.
2.7 EXIT DEVICES A. Acceptable Manufacturers: Sargent Precision WD 8600 2700 Series Series 80 Series Apex Series Comply with manufacturer’s instructions for concealed vertical rods. Bottom rods not required. B. Provide exit device series and functions as specified in Hardware Groups. Precision product numbers are referenced in the Hardware Groups. C. All exit devices shall be UL listed for panic. Exit devices for labeled doors shall be UL listed as "Fire Exit Hardware". D. Lever trim shall be rigid when in the locked position and able to withstand 1000 inch pounds of force without allowing access. E. All trim shall be thru-bolted if recommended. F. All lever trim shall be made of a cast material available in all the architectural finishes and designs to match the locksets specified. 6.19 08710 - 8 394.107.001 SECTION 08710
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G. All exit devices are to be certified to meet ANSI/BHMA 156.3 Grade 1 Requirements. H. Mounting rails shall be formed of a solid single piece of stainless steel, brass or bronze depending upon finish. I. All exit devices installed on fire rated doors shall be thru-bolted. J. Push rails are to be formed of the same material and in the same manner as the mounting rails. K. All end caps shall be made of the same base metal as the mounting and push rails. L. All chassis shall be a heavy-duty cast design with one-piece drawn non-ferrous removable cover matching the material and finish of the mounting and push rails. M. The design of the device shall eliminate the necessity of removing the device from the door for standard maintenance or keying changes. N. Provide keyed removable mullions, as specified in the Hardware Groups. O. Finish as defined under Section 2.21
2.8 DOOR TRIM A. Acceptable Manufacturers and Types: Manufacturer Type Product Number Rockwood Push/Pull Set 111 x 73C x 73L type 9 Mounting Burns Push/Pull Set 7426C x 74 Back to Back Mounting
B. Push Plates: 1. Rockwood type 73C unless otherwise indicated. C. Pulls: Rockwood 111x73C, unless otherwise indicated. 1. Mount back to back with push plate F. Kick Plates and Armor Plates: Minimum of 0.050 inch thick, beveled 4 edges. 1. At single doors provide width 1-1/2 inch less than door width on stop side and one inch less than door width on face side. 2. At pairs of doors provide width one inch less than door width on both sides. 3. Height of 12 inches, unless otherwise indicated. 4. Countersink all holes.
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G. Finish as defined under section 2.21
2.9 DOOR VIEWERS A. Acceptable Manufacturers:
Rockwood Ives 620 U696
B. Door viewers shall have a minimum of 150deg view. C. Door Viewers shall be UL listed D. Door Viewers shall be installed with a thread locking material. E. Finish as defined under section 2.21
2.10 DOOR CLOSERS A. Acceptable Manufacturers and Types of Exposed Closers: Sargent LCN Norton 351 SERIES 4111 SERIES 7500 SERIES
B. Provide non-sized closers, adjustable to meet maximum opening force requirements of ADA. C. Provide drop plates, brackets, or adapters for arms as required to suit details. D. Mount closers on room side of corridor doors and inside of exterior doors. E. Provide adjustable back-check for closers. F. All closers mounted on fire rated doors shall be thru-bolted. G. Provide hold-open arms where indicated. H. Where Parallel arm closers are used, use manufacturers heaviest duty arm. I. Provide closers for doors as noted in Hardware Groups and, in addition, provide closers for labeled doors whether or not specifically noted in groups. J. Provide closers meeting the requirements of UBC 7-2 and UL 10C positive pressure tests.
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K. Finish as defined under section 2.21
2.11 OVERHEAD STOPS/HOLDERS A. Acceptable Manufacturers: Sargent ABH Glynn Johnson 590 9000 900 690 1000 100
B. Provide 590 Series overhead stops/holders for doors not equipped a closer that will not swing to a wall, and for doors that open against equipment, other doors, casework, sidelights, other objects that would make wall stops inappropriate.
C. Provide 690 Series overhead stop/holders for doors equipped with closers that will not swing to a wall, and for doors that open against equipment, other doors, casework, sidelights, other objects that would make wall stops inappropriate. D. Provide sex bolt attachments for all wood door applications. E. All vestibule doors are to have a 690 Series stop or holder. F. Finish as defined under section 2.21
2.12 WALL STOPS AND HOLDERS A. Acceptable Manufacturers and Types: Rockwood Burns Ives 403 565 x PDA 402 ½ x PDA 405 565 x ES 402½ x ES 471 525 x ES 443
B. Provide 403 or 405 Series wall stop as applicable. C. Provide overhead stop/holders for doors that swing more than 140 degrees before striking a wall, and for doors that open against equipment, other doors, casework, sidelights, other objects that would make wall stops inappropriate. D. Provide 471 Floor stop only where specified or absolutely unavoidable. E. Finish as defined under Section 2.21
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2.13 THRESHOLDS A. Acceptable Manufacturers: Pemko, Reese Enterprises, and National Guard Products.
Pemko Reese National Guard 271 S406 613
B. Where thresholds are specified in hardware groups, provide 613 thresholds unless detailed otherwise. 1. Refer to drawings for special details. Provide accessories, shims and fasteners. 2. Where thresholds occur at openings with one or more mullions, they shall be cut for the mullions and extended continuously for the entire opening. 3. Finish as defined under section 2.21
2.14 WEATHERSTRIPPING A. Acceptable Manufacturers and Product: Pemko Reese National Guard Sweeps 18061_P F964 607 Head & Jambs 18061_P F964 607 Drip Caps 346 R201 16_D Astragal (2) 18061_P (2) F964 (2) 607 Auto Door 4131_RL 330 420N Bottom Sound Seals 379_R 33 1038N
B. Where weather-stripping is specified in hardware groups, provide C607 at head and jambs unless detailed otherwise. C. Weather-stripping and Astragals for aluminum doors to be provided by aluminum door manufacture. D. Thresholds and Sweeps for aluminum doors are to be provided under this section. E. Provide self-tapping fasteners for weather-stripping being applied to hollow metal frames. F. Where sweeps are specified in hardware groups, provide 607 unless detailed otherwise. G. Provide 346 x full frame width at all out-swinging hollow metal frames, unless detailed otherwise. H. Finish as defined under Section 2.21 6.19 08710 - 12 394.107.001 SECTION 08710
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2.15 MAGNETIC HOLDERS (NOT APPLICABLE) A. Acceptable Manufacturers and Types: Sargent Rixson ABH 1504 FM-998 2100
B. Magnetic holders shall have minimum holding force of 35 lbs. C. Magnetic holders shall fit into a standard outlet box. D. Voltage shall be 24V AC/DC or 120VAC field selectable. E. Standard armature projection to be 1 5/8” field adjustable up to 3” F. Must meet ANSI A156.15 G. Must be UL Listed to U.S. safety standards
2.16 AUTOMATIC DOOR CLOSERS (NOT USED) A. Acceptable Manufacturers and Types: Imperial Door Norton NABCO 4100LE 6900 Powermatic GT System 710
B. Door Operator shall provide conventional door closer opening and closing forces unless the power operator motor is activated.
C. Door Operator shall have an adjustable hydraulic backcheck valve to cushion the door speed if opened violently
D. Door Operator shall be AUTOMATICALLY ACTIVATED by either a slight push or pull in the direction of opening swing.
E. Door Operator shall be SELECTIVELY ACTIVATED by external initiating device.
F. Door Operator shall be both AUTOMATICALLY ACTIVATED and SELECTIVELY ACTIVATED.
G. Switched to indefinite hold open function or switched “OFF” which will disable function inputs allowing unit to be used as a manual door closer.
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H. Unit shall be U.L. Listed for automatic closing door.
I. The door shall be powered from a door closed position to a full door open position and remain in momentary hold open for up to 30 seconds.
J. Push button plates (Handicapped markings) for standard pole mount, jamb mount or railing mount.
2.17 ELECTRIC STRIKES A. Acceptable Manufacturers and Types: Von Duprin Trine/Axion Hes 5100 3234 7000
H. 12 volt DC solenoid operation. Separate Power pack. I. Exchangeable between fail safe and fail secure. J. Heavy Duty construction. K. Adjustable keeper, tamper resistant design.
2.18 KEY CABINET (LOCATE IN MECHANICAL/STORAGE ROOM 115) A. Provide key cabinets by Lund Equipment, Telkee Incorporated, or Key Control. B. Lund Deluxe wall type cabinet, Series 1200. C. Provide cabinet with one hook for each lock or cylinder plus at least 50 percent extra hooks. D. Provide each hook with one non-removable security key tag and one snap-on link duplicate key tag. E. Provide tools, instruction sheets and accessories required to complete installation. F. Owner will place keys in key cabinet and complete index cards furnished with key system.
2.19 FASTENERS A. Including, but not limited to, wood or machine screws, bolts, bolts, nuts, anchors, etc. of proper type, material, and finish required for installation of hardware. B. Use Phillip head for exposed screws. Do not use aluminum screws to attach hardware. 6.19 08710 - 14 394.107.001 SECTION 08710
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C. Provide self-tapping (TEC) screws for attachment of sweeps and stop-applied weather- stripping.
2.20 TYPICAL FINISHES AND MATERIALS A. Finishes, unless otherwise specified: Hardware finish to be US26D.
PART 3 EXECUTION
3.1 EXAMINATION A. Examine doors, frames, and related items for conditions that would prevent the proper application of finish hardware. Do not proceed until defects are corrected.
3.2 INSTALLATION A. Install finish hardware in accordance with reviewed hardware schedule and manufacturer's printed instructions. Pre-fit all hardware before finish is applied, remove and reinstall after finishing is completed. Install hardware so that parts operate smoothly, close tightly and do not rattle. B. Installation of hardware shall comply with NFPA 80 and NFPA 101 requirements. C. All doors shall be installed where permitted to swing 180 degrees. Exceptions as noted under Section 2.12 OVERHEAD STOPS/HOLDERS. D. Set units level, plumb and true to line and location. Adjust and reinforce attachment to substrate as necessary for proper installation and operation. E. Drill and countersink units, which are not factory-prepared for anchorage fasteners. Space fasteners and anchors in accordance with industry standards. F. Set thresholds for exterior doors in full bed of butyl rubber or polyisobutylene mastic sealant, forming tight seal between threshold and surface to which set. Securely and permanently anchor thresholds, using countersunk non-ferrous screws to match color of thresholds (stainless steel screws at aluminum thresholds).
3.3 FIELD QUALITY CONTROL A. After installation has been completed, provide services of qualified hardware consultant to check Project to determine proper application of finish hardware according to schedule. Also check operation and adjustment of hardware items.
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B. Adjust door control devices to compensate for final operation of heating and ventilating equipment.
3.4 ADJUSTING AND CLEANING A. At final completion, hardware shall be left clean and free from disfigurement. Make final adjustment to door closers and other items of hardware. Where hardware is found defective repair or replace or otherwise correct as directed. B. Adjust door closers to meet opening force requirements of Uniform Federal Accessibility Standards. C. Final Adjustment: Wherever hardware installation is made more than one month prior to acceptance or occupancy of space or area, return to work during week prior to acceptance or occupancy, and make final check and adjustment of hardware items in such space or area. Clean operating items as necessary to restore proper function and finish of hardware and doors. D. Instruct Owner's personnel in proper adjustment and maintenance of door hardware and hardware finishes. E. Clean adjacent surfaces soiled by hardware installation.
3.5 PROTECTION AND ADDITIONAL STOCK A. Provide for proper protection of items of hardware until Owner accepts Project as complete.
B. Provide additional stock of 1 unit of each type of hardware device used in the project.
3.6 HARDWARE GROUPS AND SUFFIXES A. The following schedule of hardware groups shall be considered a guide only, and the supplier is cautioned to refer to general conditions, special conditions, and the preamble to this section. It shall be the hardware supplier's responsibility to furnish all required hardware. B. Refer to the door schedule for hardware group required at each door opening. Ignore hardware groups not used on the door schedule.
6.19 08710 - 16 394.107.001 SECTION 08710
FINISH DOOR HARDWARE
3.7 HARDWARE GROUPS Hardware Group 1 Single Metal Entry Door CARD/KEY PAD READER UNLOCKS LOCKSET. OUTSIDE LEVER ALWAYS LOCKED WITH POWER APPLIED TO SOLENOID. LEVER UNLOCKS BY CARD/KEY PAD READER OR REMOTE CONTROL, LOSS OF POWER, OR FIRE ALARM ACTIVATION, CARD/KEY PAD READER OR REMOTE CONTROL AS PER ELECTRICAL SPECIFICATIONS PROVIDED UNDER ELECTRICAL CONTRACT.
1 EA Rim Mounted Surface Panic Device/Lever Trim 1 EA ELECTRIC STRIKE 1 EA POWER SUPPLY 1 EA Continuous Hinges 1 EA Weatherstripping 1 EA Aluminum Threshold x width of opening 1 EA Push and/or Pull 3 EA Silencers
Hardware Group 2 Single Metal Door
3 EA Hinges 1 EA Aluminum Threshold x width of opening 1 EA Push and/or Pull 3 EA Silencers
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT – FINISH DOOR HARDWARE
A. Measurement for Finish Door Hardware shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT – FINISH DOOR HARDWARE
A. For Finish Door Hardware, not included in other unit or lump sum price items, payment for Finish Door Hardware will be made at the applicable price stated in the Bid.
END OF SECTION 6.19 08710 - 17 394.107.001 SECTION 09900
PAINTING
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Painting as shown on the Plans, as specified and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 Code of Federal Regulations (CFR) Publications:
29 1910.1000 Occupational Safety and Health Standards
29 1910.1025 Occupational Safety and Health Standards (Lead)
1.2.2 Federal Standard (FED-STD):
313 Material Safety Data Sheets Preparation and Submission of
1.2.3 Steel Structures Painting Council (SSPC) Publications:
Paint-1 Shop, Field, and Maintenance Painting
Paint-3 A Guide to Safety in Paint Application
Paint-20 Zinc-Rich Primers (Type I, Inorganic, and Type II Organic)
SP 1 Solvent Cleaning
SP 2 Hand Tool Cleaning
SP 3 Power Tool Cleaning
SP 6 Commercial Blast Cleaning
SP 7 Brush-Off Blast Cleaning
6.19 09900-1 394.107.001 SECTION 09900
PAINTING
SP 10 Near-White Blast Cleaning
VIS1 Pictorial Surface Preparation Standards for Painting Steel Surfaces, Guide to
1.3 SUBMITTALS: Submit the following.
1.3.1 Manufacturer's Instructions:
a. Paint application instructions
b. Manufacturer's material safety data sheets
Submit Manufacturer's material safety data sheets for coatings, solvents, and other potentially hazardous materials, as defined in FED-STD-313.
1.4 REGULATORY REQUIREMENTS:
1.4.1 Lead Content: Do not use coatings having a lead content over 0.06 percent by weight of nonvolatile content.
1.4.2 Chromate Content: Do not use coatings containing zinc-chromate or strontium-chromate.
1.4.3 Asbestos Content: Materials shall not contain asbestos.
1.5 DELIVERY AND STORAGE: Deliver materials in sealed, labeled containers bearing the manufacturer's name, brand designation, specification number, batch number, color, and date of manufacture. Restrict storage and mixing of materials to locations designated by the Engineer.
1.6 SAFETY METHODS: Apply coating materials using safety methods and equipment in accordance with the following:
1.6.1 Safety Methods Used During Coating Application: Comply with the requirements of SSPC Paint-3.
6.19 09900-2 394.107.001 SECTION 09900
PAINTING
1.6.2 Toxic Materials: To protect personnel from overexposure to toxic materials, conform to the most stringent guidance of:
a. The chemical manufacturer when using mineral spirits, or other chemicals. Use impermeable gloves, chemical goggles or face shield, and other recommended protective clothing and equipment to avoid exposure of skin, eyes, and respiratory system. Conduct work in a manner to minimize exposure of building occupants and the general public.
b. The appropriate OSHA standard in 29 CFR 1910.1025 for surface preparation on painted surfaces containing lead, zinc-chromate, strontium-chromate, asbestos, or other toxic ingredients.
c. 29 CFR 1910.1000.
d. Threshold Limit Values (R) of the American Conference of Governmental Industrial Hygienists.
e. Manufacturer's Material Safety Data Sheets (MSDS).
1.7 ENVIRONMENTAL CONDITIONS:
1.7.1 Exterior Coatings: Do not apply coating to surfaces during foggy or rainy weather, or under the following surface temperature conditions:
a. Less than 5 degrees F above the dew point;
b. Below 40 degrees F (for oil-based paints), 50 degrees F (for latex paints), or over 95 degrees F, unless approved by the Engineer.
1.7.2 Interior Coatings: Apply coatings when surfaces to be painted are dry and the following surface temperatures can be maintained:
a. Between 65 and 95 degrees F during the application of enamels and varnishes;
b. Between 50 and 95 degrees F during the application of other coatings.
6.19 09900-3 394.107.001 SECTION 09900
PAINTING
1.8 COLOR SELECTION: Colors of finish coats shall be as indicated or specified. Where not indicated or specified, colors shall be selected by the Engineer.
1.9 LOCATION AND SURFACE TYPE TO BE PAINTED:
1.9.1 Painting Included: Where a space or surface is indicated to be painted, include the following unless indicated otherwise.
a. Surfaces behind portable objects and surface mounted articles readily detachable by removal of fasteners, such as screws and bolts.
b. New factory finished surfaces that require identification or color coding and factory finished surfaces that are damaged during performance of the work.
c. Existing coated surfaces that are damaged during performance of the work.
1.9.2 Painting Excluded: Do not paint the following unless indicated otherwise.
a. Surfaces concealed and made inaccessible by panelboards, fixed ductwork, machinery, and equipment fixed in place.
b. Surfaces in concealed spaces. Concealed spaces are defined as spaces above suspended ceilings, furred spaces, attic spaces, crawl spaces, and chases.
c. Steel to be embedded in concrete.
d. Copper, stainless steel, aluminum, brass, and lead except existing coated surfaces.
1.9.3 Exterior Painting: Includes new surfaces of the building site work items and appurtenances. Also included are existing coated surfaces made bare by cleaning operations.
1.9.4 Interior Painting: Includes new surfaces of the building and appurtenances as indicated and existing coated surfaces made bare by cleaning operations. Where a space or surface is indicated to be painted, include the following items, unless indicated otherwise.
a. Exposed columns, girders, beams, joists, and metal deck; and b. Other contiguous surfaces.
6.19 09900-4 394.107.001 SECTION 09900
PAINTING
1.9.5 Mechanical and Electrical Painting: Includes field coating of interior and exterior new] surfaces.
a. Where a space or surface is indicated to be painted, include the following items unless indicated otherwise.
(1) Exposed piping, conduit, and ductwork;
(2) Supports, hangers, air grilles, and registers;
(3) Miscellaneous metal work and insulation coverings.
b. Do not paint the following, unless indicated otherwise:
(1) New zinc-coated, aluminum, and copper surfaces under insulation;
(2) New aluminum jacket on piping; and
(3) New interior ferrous piping under insulation.
PART 2 - PRODUCTS
2.1 MATERIALS: Provide as far as practical, pretreatments, primers and top coats from one coating manufacturer. Coatings shall be applied as a complete system and must be compatible with the substrate and each coating component. Coating systems shall be the manufacturer's industrial or commercial systems and are specified by generic type only. Residential coating systems shall not be permitted.
PART 3 - EXECUTION
3.1 PROTECTION OR AREAS AND SPACES: Prior to surface preparation and coating applications, remove, mask, or otherwise protect, hardware, hardware accessories, machined surfaces, radiator covers, plates, lighting fixtures, public and private property, and other such items not to be coated that are in contact with surfaces to be coated. Following completion of painting, workmen skilled in the trades involved shall reinstall removed items. Restore surfaces contaminated by coating materials, to original condition and repair damaged items.
6.19 09900-5 394.107.001 SECTION 09900
PAINTING
3.2 SURFACE PREPARATION: Remove dirt, splinters, loose particles, grease, oil, disintegrated coatings, and other substances deleterious to coating performance as specified for each substrate.
3.3 PREPARATION OF METAL SURFACES:
3.3.1 Existing and New Ferrous Surfaces:
a. Shop-coated Surfaces and Small Areas That Contain Rust, Mill Scale and Other Foreign Substances: Solvent clean in accordance with SSPC SP1 to remove oil and grease. Where shop coat is missing or damaged, clean according to SSPC SP2 or SSPC SP3.
b. Surfaces With More Than 20 Percent Rust, Mill Scale, and Other Foreign Substances: Clean entire surface in accordance with SSPC SP6.
c. Galvanized steel shall be prepared for painting in accordance with ASTM D6386.
3.3.2 Final Ferrous Surface Condition: Cleaned surface shall be similar to photographs in SSPC VIS1 as follows:
DEGREE OF ADHERENT RUSTING PITTED AND CLEANING MILL SCALE MILL SCALE RUSTED RUSTED
Hand Tool Cleaning (1) B St 2 C St 2 D St 2 SSPC SP 2
Power Tool Cleaning (1) B St 3 C St 3 D St 3 SSPC SP 3
Commercial Blast (1) (1) C Sa 2 D Sa 2 Cleaning SSPC SP 6
Brush-Off Blast (1) B Sa 1 C Sa 1 D Sa 1 Cleaning SSPC SP 7
Note: (1) No photograph is available or recommended for comparison
6.19 09900-6 394.107.001 SECTION 09900
PAINTING
3.4 PREPARATION OF CONCRETE AND CEMENTITIOUS SURFACE:
3.4.1 Concrete and Masonry:
a. Surface Cleaning: Remove the following deleterious substances. (1) Dirt, Chalking, Grease, and Oil: Wash new surfaces with a solution composed of 3 ounces (2/3 cup) trisodium phosphate, 1 ounce (1/3 cup) household detergent, and 3 quarts of warm water. Then rinse thoroughly with fresh water. For large areas, water blasting may be used.
(2) Fungus and Mold: Wash surfaces with a solution composed of 3 ounces (2/3 cup) trisodium phosphate, 1 ounce (1/3 cup) household detergent, 1 quart 5 percent sodium hypochlorite solution and 3 quarts of warm water. Rinse thoroughly with fresh water.
(3) Glaze and Loose Particles: Remove by wire brushing.
(4) Efflorescence: Remove by scraping or wire brushing followed by washing with a 5- to 10-percent by weight aqueous solution of hydrochloric (muriatic) acid. Do not allow acid to remain on the surface for more than five minutes before rinsing with fresh water. Do not acid clean more than 4 square feet of surface, per workman, at one time.
b. Cosmetic Repair of Minor Defects: Repair or fill mortar joints and minor defects, including but not limited to spalls, in accordance with manufacturer's recommendations and prior to coating application.
3.4.2 Gypsum Board:
a. Surface Cleaning: Gypsum board shall be dry. Remove loose dirt and dust by brushing with a soft brush or rubbing with a dry cloth prior to application of the first coat material.
b. Repair of Minor Defects: Prior to painting, repair joints, cracks, holes, surface irregularities, and other minor defects with spackling compound and sand smooth.
6.19 09900-7 394.107.001 SECTION 09900
PAINTING
3.5 APPLICATION:
3.5.1 Coating Application: Apply coating materials in accordance with SSPC Paint-1. SSPC Paint-1 methods are applicable to all substrates, except as modified herein. Thoroughly work coating materials into joints, crevices, and open spaces. Touch up damaged coatings before applying subsequent coats. Interior areas shall be broom clean and dust free before and during the application of coating material.
a. Drying Time: Allow time between coats, as recommended by the coating manufacturer, to permit thorough drying. Provide each coat in specified condition to receive the next coat.
b. Primers, and Intermediate Coats: Do not allow primers or intermediate coats to dry more than 30 days, or longer than recommended by the manufacturer, before applying subsequent coats. Follow manufacturer's recommendations for surface preparation if primers or intermediate coats are allowed to dry longer than recommended by manufacturers of subsequent coatings. Each coat shall cover the surface of the preceding coat or surface completely, and there shall be a visually perceptible difference in shades of successive coats.
c. Finished Surfaces: Provide finished surfaces free from runs, drops, ridges, waves, laps, brush marks, and variations in colors.
3.5.2 Equipment: Apply coatings with approved brushes, approved rollers, or approved spray equipment, unless specified otherwise. Spray areas made inaccessible to brushing by items such as ducts and other equipment.
3.5.3 Thinning of Paints: Reduce paints to proper consistency by adding fresh paint, except when thinning is mandatory for the type of paint being used. Obtain written permission from the Engineer to use thinners. The written permission shall include quantities and types of thinners to use.
3.5.4 Coating Systems:
a. Systems by Substrates: Apply coatings that conform to the respective specifications listed in the following Tables:
6.19 09900-8 394.107.001 SECTION 09900
PAINTING
Table I Exterior Metal Surfaces II Interior Metal Surfaces III Exterior Concrete Surfaces IV Interior Concrete Surfaces V Exterior Masonry Surfaces VI Interior Masonry Surfaces VII Interior Gypsum Wallboard Surfaces VIII Exterior and Interior Wood Surfaces
b. Minimum Dry Film Thickness (DFT): Apply paints, primers, varnishes, enamels, undercoats, and other coatings to a minimum dry film thickness of 1.5 mil each coat unless specified otherwise in the Tables. Coating thickness where specified, refers to the minimum dry film thickness.
c. Coatings for Surfaces Not Specified Otherwise: Coat surfaces which have not been specified, the same as surfaces having similar conditions of exposure.
d. Existing Surfaces Damaged During Performance of the Work, Including New Patches In Existing Surfaces: Coat surfaces with the following:
(1) One coat of primer.
(2) One coat of undercoat or intermediate coat.
(3) One top coat to match adjacent surfaces.
e. Existing Coated Surfaces To Be Painted: Apply coatings conforming to the respective specifications listed in the Tables herein, except that pretreatments, sealers, fillers, and primers need not be provided on surfaces where existing coatings are soundly adhered and in good condition.
3.6 COATING SYSTEMS FOR METAL:
a. Primer: Apply specified ferrous metal primer on the same day that surface is cleaned. If flash rusting occurs, re-clean the surface prior to application of primer.
6.19 09900-9 394.107.001 SECTION 09900
PAINTING
(1) Inaccessible Surfaces: Prior to erection, use two coats of the specified primer on metal surfaces that will be inaccessible after erection.
(2) Shop-primed Surfaces: Touch up exposed substrates and damaged coatings to protect from rusting prior to applying field primer.
(3) Pipes and Tubing: The semitransparent film applied to pipes and tubing at the mill is not to be considered a shop coat. Apply specified ferrous metal primer prior to application of subsequent coats.
(4) Exposed Nails, Screws, Fasteners, and Miscellaneous Ferrous Surfaces: On surfaces to be coated with water thinned coatings, spot prime exposed nails and other ferrous metal with latex primer.
b. Apply coatings of Tables I and II. "DFT" means dry film thickness in mils.
3.7 COATING SYSTEMS FOR WOOD AND PLYWOOD:
a. Apply coatings of Tables VII and VIII.
b. Prior to erection, apply two coats of the specified primer to treat and prime wood and plywood surfaces which will be inaccessible after erection.
3.8 INSPECTION AND ACCEPTANCE: In addition to meeting the previously specified requirements, demonstrate the mobility of moving components, including but not limited to swinging and sliding doors, cabinets, and windows with operable sash, for inspection by the Engineer. Perform this demonstration after appropriate curing and drying times of the coatings have elapsed and prior to invoicing for final payment.
TABLE I EXTERIOR METAL SURFACES
CONDITION PREPARATION FIRST COAT DFT SECOND COAT DFT THIRD COAT DFT
Severe SSPC SP 6 Epoxy-Polyamide 4.0 Aliphatic Polyester 1.5 - - Polyurethane
Mild SSPC SP 6 Alkyd-Phenolic 2.0 Alkyd 1.5 Alkyd 1.5 Primer
6.19 09900-10 394.107.001 SECTION 09900
PAINTING
TABLE II INTERIOR METAL SURFACES
CONDITION PREPARATION FIRST COAT DFT SECOND COAT DFT THIRD COAT DFT
Severe SSPC SP 6 Epoxy-Polyamide 3.0 Epoxy-Polyamide 4.0 - - Primer
Mild SSPC SP 6 Alkyd-Phenolic 2.0 Alkyd 1.5 Alkyd 1.5 Primer
Immersion SSPC SP 10 Coal-Tar Epoxy 14.0 - - - -
TABLE III EXTERIOR CONCRETE SURFACES
CONDITION PREPARATION FIRST COAT DFT SECOND COAT DFT THIRD COAT DFT
Severe Clean and Dry Modified Epoxy 8.0 - - - -
Mild Clean and Dry Emulsified Acrylic 2.0 Emulsified Acrylic 2.0 - -
TABLE IV INTERIOR CONCRETE SURFACES
CONDITION PREPARATION FIRST COAT DFT SECOND COAT DFT THIRD COAT DFT
Severe Brush Blast Epoxy-Polyamide 4.0 Epoxy-Polyamide 4.0 - - Water-Borne Water-Borne
Moderate Brush Blast Acrylic-Epoxy 2.0 Acrylic-Epoxy 2.0 -- -
Mild Clean and Dry Emulsified Acrylic 2.0 Emulsified Acrylic 2.0 -
Concrete Acid Etch or Epoxy-Polyamide 2.0 Epoxy-Polyamide 2.0 - - Floors Brush Blast (skid resistant)
6.19 09900-11 394.107.001 SECTION 09900
PAINTING
TABLE V EXTERIOR MASONRY SURFACES
CONDITION PREPARATION FIRST COAT DFT SECOND COAT DFT THIRD COAT DFT
All Clean and Dry Modified Epoxy 60 Modified Epoxy 8.0 - - sf/gal
TABLE VI INTERIOR MASONRY SURFACES
CONDITION PREPARATION FIRST COAT DFT SECOND COAT DFT THIRD COAT DFT
Severe Clean and Dry Epoxy-Polyamide 75 Epoxy-Polyamide 4.0 Epoxy-Polyamide 4.0 Filler sf/gal
Mild Clean and Dry Modified Epoxy 60 Emulsified Acrylic 2.0 Emulsified Acrylic 2.0 Filler sf/gal
TABLE VII INTERIOR GYPSUM WALL BOARD SURFACES
CONDITION PREPARATION FIRST COAT DFT SECOND COAT DFT THIRD COAT DFT
New Clean and Dry Latex Primer 2.0 Acrylic Latex 2.0 - -
TABLE VIII EXTERIOR AND INTERIOR WOOD SURFACES
CONDITION PREPARATION FIRST COAT DFT SECOND COAT DFT THIRD COAT DFT
All Clean and Dry Alkyd Primer 2.0 Alkyd 1.5 Alkyd 1.5
6.19 09900-12 394.107.001 SECTION 09900
PAINTING
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - PAINTING:
4.1.1 Measurement for Painting shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - PAINTING:
4.2.1 For Painting, not included in other unit or lump sum price items, payment for Painting will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 09900-13 394.107.001 SECTION 10800
TOILET AND BATH ACCESSORIES
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Toilet and Bath Accessories, as shown on the Plans, as specified, and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American National Standards Institute, Inc. (ANSI) Publication:
A117.1 1986 Providing Accessibility and Usability for Physically Handicapped People
1.2.2 Federal Specifications (Fed. Spec.):
WW-H-1911A Holder, Toilet Paper (Single Roll)
WW-P-541/8B Plumbing Fixture (Accessories, Land Use) (Detail Specification)
1.3 SUBMITTALS:
1.3.1 Manufacturer's Catalog Data: Submit for each type of accessory specified. Include descriptions of materials, finishes, fastening and anchoring devices, and appurtenances.
1.4 DELIVERY AND STORAGE: Deliver materials to the site in unopened containers, labeled with the manufacturer's names and brands, ready for installation. Store accessories in safe, dry locations until needed for installation.
PART 2 - PRODUCTS
2.1 MATERIALS AND FABRICATION: Fabricate accessories in accordance with commercial practice, with welds ground smooth. Bend, flange, draw, form, and perform similar operations in a manner to ensure no defects. Doors shall be warp free. Key manufacturer's standard locks alike, for groups of accessories; two keys furnished for each group.
6.19 10800-1 394.107.001 SECTION 10800
TOILET AND BATH ACCESSORIES
2.2 FINISHES: Finishes on metals not specified otherwise shall be provided as follows:
Metal Finish
Corrosion-resisting Steel General-purpose Polished (Stainless Steel) Aluminum Satin Anodic, Clear Carbon Steel Bright Chromium Plate Copper Alloy (Brass) Bright Chromium Plate Zinc Alloy Bright Chromium Plate
2.3 MANUFACTURED UNITS:
2.3.1 Multi Purpose Unit (Recessed): Fabricate from stainless steel.
2.3.1.1 Paper Towel Dispenser and Waste Receptacle: CID A-A-2380, Type III, (C-fold Towels). Minimum thickness of uncoated metal 0.029 inch. Satin finish stainless steel. Minimum capacity 400 towels. Removable waste receptacle to have 12 gallon capacity.
2.3.2 Soap Dispensers: Rectangular vessel, liquid soap dispersed by spring action "push-in" valve, capacity of 40 fluid ounces. Satin finish stainless steel.
2.3.3 Mirrors: Fabricate from not less than 20 gauge polished stainless steel. Units shall be 24 inches wide by 36 inches high, surface mounted frameless type with hemmed edges and hardboard substrate.
2.3.4 Toilet Tissue Dispensers (Surface Mounted):
2.3.4.1 Type I, Roller Mounted on Support Brackets for Two Rolls: Fed. Spec. WW-H-1911, spring actuated chromium plated copper alloy roller. Stainless steel posts.
2.3.5 Grab Bars: Fed. Spec. WW-P-541/8B, Type IV, Class 2, surface mounted, stainless steel, 1-1/4 inches in diameter, with a nominal wall thickness of not less than 0.50 inch (18 gauge), of the length and shape indicated and with a non-slip finish. Grab bars and mounting devices shall be capable of withstanding a static load of 250 pounds at any point on the bar.
2.3.5.1 Grab Bars to be ADA complaint at water closet:
- 36” horizontal grab bar located on wall behind water closet, 36” above finished floor, maintain exact 12” x 24” split over centerline of water closet.
6.19 10800-2 394.107.001 SECTION 10800
TOILET AND BATH ACCESSORIES
- 42” horizontal grab bar located on wall adjacent to water closet (Water closet 16-18” on center away from wall), located 12” away from wall behind water closet. - 18” vertical grab bar located on wall adjacent to water closet (Above 42” grab bar). Center line of vertical grab bar to be 42” above finish floor.
2.3.6 Robe Hooks: Provide two hooks integral with the wall flange. Projection shall be not less than 1-5/8 inches from the back of the wall flange to the end of the hooks. Hooks shall be stainless steel, cooper alloy, or aluminum alloy.
2.3.7 Surface Mounted Sanitary Napkin Disposal: Units fabricated of 22 gage stainless steel with exposed surfaces in architectural satin finish. Push flap door to be fabricated of 22 gage stainless steel with exposed surfaces in architectural satin finish . Door to have heavy duty stainless steel piano hinge and be self closing. Unit to have tumble locks keyed to match other accessories. Disposal to have 1.5 gallon capacity.
PART 3 – EXECUTION
3.1 INSTALLATION: Surfaces of fastening devices exposed after installation shall have the same finish as the attached accessory. Exposed screw heads shall be oval. Install accessories at the location and height per manufacturer's written installation instructions. Accessories designed for use by the physically handicapped shall be installed in accordance with ANSI A117.1. Protect exposed surfaces of accessories with strippable plastic or by other means until the installation is accepted. After acceptance of accessories, remove and dispose of strippable plastic protection. Coordinate accessory manufacturer's mounting details with other trades as their work progresses. After installation, thoroughly clean exposed surfaces and restore damaged work to its original condition or replace with new work.
3.1.1 Surface-Mounted Accessories: Mount on concealed backplates, unless specified otherwise. Accessories without backplates shall have concealed fasteners. Unless indicated or specified otherwise, install accessories with sheet metal screws or wood screws in lead-lined braided jute, Teflon or neoprene sleeves, or other approved fasteners as required by the construction. Install backplates in the same manner, or as required by the construction. Fasten accessories without solid backing into the studs, or provide wood blocking secured to studs.
6.19 10800-3 394.107.001 SECTION 10800
TOILET AND BATH ACCESSORIES
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - TOILET AND BATH ACCESSORIES:
4.1.1 Measurement for Toilet and Bath Accessories shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - TOILET AND BATH ACCESSORIES:
4.2.1 For Toilet and Bath Accessories, not included in other unit or lump sum price items, payment for Toilet and Bath Accessories will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 10800-4 394.107.001 SECTION 13121
PREENGINEERED METAL BUILDINGS (RIGID FRAME)
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Preengineered Metal Buildings (Rigid Frame), as shown on the Plans, as specified and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American Architectural Manufacturers Association (AAMA) Publication:
101 Voluntary Specifications for Aluminum Prime Windows and Sliding Glass Doors
1.2.2 American Institute of Steel Construction (AISC) Publication:
SCM Steel Construction Manual
1.2.3 American Iron and Steel Institute (AISI) Publication:
SG671 Design of Cold-Formed Steel Structural Members
1.2.4 American National Standards Institute, Inc. (ANSI) Publication:
A58.1 Minimum Design Loads for Buildings and Other Structures
1.2.5 American Society for Testing and Materials (ASTM) Publications:
A463 Steel Sheet, Cold-Rolled, Aluminum-Coated, Type 1 and Type 2
A755 Steel Sheet, Zinc-Coated (Galvanized) by the Hot-Dip Process and Coil-Coated for Roofing and Siding, General Requirements
6.19 13121-1 394.107.001 SECTION 13121
PREENGINEERED METAL BUILDINGS (RIGID FRAME)
A792M Steel Sheet, Aluminum-Zinc Alloy-Coated by the Hot Dip Process, General Requirements (Metric)
B209 Aluminum and Aluminum-Alloy Sheet and Plate
C236 Steady-State Thermal Performance of Building Assemblies by Means of a Guarded Hot Box
C991 Flexible Glass Fiber Insulation for Metal Buildings
D828 Tensile Breaking Strength of Paper and Paperboard
D3841 Glass-Fiber-Reinforced Polyester Plastic Panels
E84 Surface Burning Characteristics of Building Materials
E96 Water Vapor Transmission of Materials
1.2.6 Uniform Fire Prevention and Building Code of New York State (UFP&BC) Publications:
BCNYS Building Code of New York State
ECCCNYS Energy Conservation Construction Code of New York State
FCNYS Fire Code of New York State
1.2.7 Building Hardware Manufacturers Association, Inc. (BHMA) Publications:
101 Butts and Hinges
301 Door Controls - Closers
601 Bored and Preassembled Locks and Latches
701 Exit Devices
6.19 13121-2 394.107.001 SECTION 13121
PREENGINEERED METAL BUILDINGS (RIGID FRAME)
1.2.8 Federal Specifications (FS):
RR-D-575 Door, Metal, Sliding and Swinging: Door Frame, Metal (Flush and Semiflush)
TT-C-520 Coating Compound, Bituminous, Solvent Type, Underbody (For Motor Vehicles)
TT-C-1796 Caulking Compounds, Metal Seam and Wood Seam
1.2.9 Metal Building Manufacturers Association (MBMA) Publication:
LRMBSM Low Rise Metal Building Systems Manual
1.2.10 Steel Window Institute (SWI) Publication:
RSSW Steel Windows
1.2.11 North American Insulation Manufacturers Association (NAIMA) Publications:
MB304 ASHRAE 90.1 Compliance For Metal Buildings
MB311 202-96 Standard For Flexible Fiber Glass Insulation to be Laminated for Use in Metal Buildings
1.2.12 National Insulation Association (NIA) Publication:
NIA 404 Certified Faced Fiber Glass Insulation for Metal Buildings
1.3 DESIGN REQUIREMENTS: MBMA LRMBSM, and AISI SG671 in accordance with the Building Code of New York State, except as specified otherwise herein. Design loads shall be as indicated and as specified herein. Building design and related foundations, shown on the Contract Drawings, are based upon estimated building frame reactions. Any foundation modifications related to different building frame reactions shall be designed and stamped by a New York State licensed Professional Engineer and performed by the Contractor and at no additional cost to the Owner.
6.19 13121-3 394.107.001 SECTION 13121
PREENGINEERED METAL BUILDINGS (RIGID FRAME)
1.3.1 Snow Loads: Loads shall be applied on the horizontal projection of the roof structure. The minimum design snow loads and adjustment factors shall be as follows:
Ground Snow Load, pg = 60 psf Snow Load Importance Factor, Is = 1.0 Terrain Category B Partially Exposed Roof Exposure Factor, Ce = 1.0 Thermal Factor, Ct = 1.0 Flat Roof Snow Load, pf = 42 psf
1.3.2 Wind Loads: The minimum design wind loads and adjustment factors shall be as follows:
Basic Wind Speed (3-second gust) = 115 MPH Exposure Category C Risk Category = II UL Class 60 Wind Uplift Resistance Rating
1.3.3 Seismic Design: The Equivalent Lateral Force procedure shall be utilized for the seismic design. The following site specific parameters for Rodman, NY shall be utilized for the seismic design:
Seismic Use Group I Mapped Spectral Response Acceleration for Short Periods, Ss = 0.186 %g Mapped Spectral Response Acceleration for a 1-Second Period, S1 = 0.073 %g Site Class D Site Coefficient, Fa = 1.6 Site Coefficient, Fv = 2.4 Design Spectral Response Acceleration, Sds = 0.199 %g Design Spectral Response Acceleration, Sd1 = 0.177 %g Seismic Design Category B Seismic Importance Factor, IE = 1.0
1.3.4 Deflection: The maximum deflection of main framing members shall not exceed 1/240th of their respective spans. The maximum deflection due to live, snow or wind load in roof panels and purlins not supporting a ceiling shall not exceed 1/180th of their respective spans. The maximum deflection due to live, snow or wind load on roof members supporting a non-plaster ceiling shall not exceed 1/240th of their respective spans. The maximum deflection
6.19 13121-4 394.107.001 SECTION 13121
PREENGINEERED METAL BUILDINGS (RIGID FRAME)
due to live, snow or wind load on roof members supporting a plaster ceiling shall not exceed 1/360th of their respective spans. The maximum deflection due to wind on wall panels and girts shall be limited to 1/120th of their respective spans except that when brittle finishes are used the maximum allowable deflection shall be limited to 1/240th of their respective spans.
1.3.5 Description of Building: Rigid frame type, similar to AISC SCM, Type I construction, utilizing tapered or uniform depth columns and beams with connections as necessary to maintain original angles between intersecting members after erection and loading. Provide bypass or inset girts. Provide rigid frames where indicated. Spacing of frames and columns shall be as indicated. End walls shall be of beam and column design. Roof slope shall be as indicated. Provide cross bracing rods; cable is not permitted. Provide portal frames where proposed cross bracing interferes with all openings. Provide full depth girts on top of masonry bond beams.
1.3.6 Fasteners: Design fastening system to withstand the design loads specified.
1.4 SUBMITTALS: Submit the following:
1.4.1 Design Data:
a. Rigid frame
b. Purlins
c. Girts
d. End frame
Submit for each component, and stamp with the seal of a Professional Engineer licensed in New York State.
1.4.2 Manufacturer's Catalog Data:
a. Preengineered metal building materials
Submit sufficient data indicating conformance to specified requirements on materials provided under this Section.
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PREENGINEERED METAL BUILDINGS (RIGID FRAME)
1.4.3 Drawings:
a. Anchor bolt layouts and sizes b. Structural connections c. Roofing and siding connections d. Joint sealing and caulking e. Door and window frame installation f. Flashings g. Accessory installation
Submit as necessary to erect the building and install components.
1.4.4 Manufacturer's Standard Color Charts:
a. Factory-finished components
Submit one sample of each color indicated for verification that the color matches the colors indicated. Where colors are not indicated, submit not less than four different samples of manufacturer's standard colors for selection by the Owner.
1.5 DELIVERY, STORAGE, AND HANDLING: Deliver, store, and handle manufactured items so that materials remain dry and undamaged. Do not store in contact with materials that might cause staining.
PART 2 - PRODUCTS
2.1 MATERIALS: MBMA LRMBSM except as specified otherwise herein. Design roof and wall panels, accessories, and flashings to be completely weathertight and free of abrasions, loose fasteners, and deformations.
2.1.1 Minimum Thickness: As required to conform to design requirements but not less than the following:
6.19 13121-6 394.107.001 SECTION 13121
PREENGINEERED METAL BUILDINGS (RIGID FRAME)
Items Minimum Thickness (Uncoated)
Steel Structural Members 18 Manufacturer's Standard Other Than Roof and Wall (MFG STD) gauge Panels
Steel Roof Panels 24 MFG STD Steel Wall Panels 26 MFG STD gauge
Steel Liner Panels 26 MFG STD gauge Trim 26 MFG STD gauge
Gable and Eave Trim, Fascia Closure Strips, Rake Flashings, Copings, and Liner Panels
Steel 26 MFG STD gauge
2.1.2 Steel Framework: Structural members having cross sectional areas other than those indicated and connections that differ from the connections indicated may be used, provided they conform to design requirements, and provided drawings indicating such changes are submitted and approved.
2.1.3 Insulated Roof Panels:
a. a. R-13ci (min.) polyisocyanurate foam core , Fabricated of aluminum-coated steel or aluminum/zinc-coated steel except as specified otherwise.
b. Preformed, with standing seam with factory-applied butyl sealant. Sheet interlocks with adjacent panel and seam are mechanically field rolled, install in full length from ridge to eaves
c. Panel clips shall be the manufacturer’s standard tall clips with thermal blocks.
2.1.4 Insulated Wall Panels:
a. a. R-13ci (min.) polyisocyanurate foam core, Fabricated of zinc-coated steel.
b. Preformed with sheet designed to overlap adjacent panel, install in full length/height from wall base to eaves
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PREENGINEERED METAL BUILDINGS (RIGID FRAME)
2.1.5 Zinc-Coated Steel Sheet: ASTM A755, Coating Class G-90.
2.1.6 Aluminum-Coated Steel Sheet: ASTM A463, Type 1 or Type 2.
2.1.7 Aluminum/Zinc-Coated Steel Sheet: ASTM A792M. Total coating weight shall be not less than 0.50 ounces per square foot.
2.1.8 Perforated Aluminum Sheet: Alloy 3004 Alclad conforming to ASTM B209.
2.1.9 Liner Panels: Formed of same type material as used for wall panels to closely approximate configuration of panels indicated.
2.1.10 Sheet Metal Accessories: Of same material and finish as used for adjacent wall or roof panels, except as specified otherwise herein.
2.1.10.1 Caps, Strips, and Plates: Form ridge caps, eave and edge strips, fascia strips, miscellaneous flashings, and miscellaneous sheet metal accessories, unless specified otherwise herein, from the same material and gauge as the roof panels. Wall plates, base angles or base channels, and other miscellaneous framing members may be standard structural steel shapes, or may be formed from steel not lighter than 18-gauge.
2.1.10.2 Gutters: Provide cross sectional area not less than the size of gutter indicated and complete with mitered corners, end pieces, and special pieces that may be required. Form gutters in sections not less than 8 feet in length. Join ends of each length with screwed and soldered joints, screwed and sealed joints, riveted and soldered joints, or riveted and sealed joints. Expansion-type slip joints shall be provided at the center of the runs and at intervals of not more than 32 feet for aluminum and not more than 40 feet for steel. Provide gutters below the slope line of the roof, to allow snow and ice to slide clear. Provide hangers of an approved type, spaced not to exceed 36 inches on center. Form hangers and fastenings from a metal compatible with the gutters.
2.1.10.3 Downspouts: Provide cross sectional area not less than the size of gutter indicated and complete including elbows and offsets. Provide downspouts in approximately 10-foot lengths; end joints shall telescope not less than 1/2 inch, and longitudinal joints shall be locked. Provide gutter outlets with stainless steel wire ball strainers of a standard type. Position downspouts not less than 1/2 inch away from walls and fasten to the walls at top, bottom, and at not to exceed 5-foot centers intermediately between with manufacturer's standard type leader straps, or concealed type fasteners. Form straps and fasteners from a metal compatible with the downspouts.
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2.1.10.4 Circular Gravity Roof Ventilators: Directional type. Ventilators shall be weatherproof under all conditions, and shall be approved standard commercial types. Reinforce and brace ventilators to provide rigid construction. Provide ventilators with bases where required; ventilator bases shall be complete with flashing flanges. Screen ventilators with 3- by 3-mesh per square inch woven galvanized steel wire bird screening. Provide screening on the exterior of frames to allow easy removal for cleaning and rewiring. Anchor ventilators to the roof in a rigid and secure manner to provide weathertight construction and to prevent vibration and movement.
2.1.10.5 Gravity (Ridge) Roof Ventilators: Provide ventilators complete with exterior windband, integral rain cone, braces, chain-operated dampers, and bird screening. Provide ventilators in sections 8 or 10 feet long, and provide bracing at 4- or 5-foot intervals. Join sections together with splice plates of the same material as the sections. Form joints in a manner which will ensure weathertightness. Provide end closures for each section where intermittent installation is indicated. Throat size (vent opening) shall be as indicated. Screen ventilators with 3- by 3-mesh per square inch woven galvanized steel wire bird screening.
2.1.11 Closure Strips: Formed of approved compressed rubber, synthetic rubber, bituminous impregnated materials, or metal of the same respective type as the roof and wall panels, and as standard with the manufacturer. Molded closure strips shall be free of open voids and shall not absorb or retain water. Form closure strips to match the corrugations or configurations of the roofing or siding used. Provide closure strips where indicated and where necessary to ensure weathertight construction.
2.1.12 Joint Sealing Material: Seal side and end laps with Type II, Class B ribbon form sealant conforming to FS TT-C-1796, except that bituminous type materials shall not be used. Minimum sizes of ribbons shall be 3/32 by 1/2 inch or 3/16 by 1/4 inch for rectangular areas and 1/4 inch diameter for circular areas. Seal joints at doors, windows, accessories, and flashings.
2.1.13 Fasteners: Fasteners for attachment to structural supports and to adjoining panels shall be as approved, and in accordance with the manufacturer's recommendation.
a. Either self-tapping screws, self-drilling screws, bolts and nuts, self-locking rivets, self-locking bolts, end-welded studs, bolted or riveted studs, or step rivets held by aluminum straps unless specified otherwise herein.
b. Stainless steel, zinc-coated steel, cadmium-plated steel, aluminum, or coated steel which has comparable corrosion-resistant properties as found in zinc coating.
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Other types of fasteners of the building manufacturer's standard type may be used if prior approval is obtained from the Engineer. The fastening system shall be fabricated to withstand the design loads specified herein. Fasteners, with the exception of those having integral hex washer heads or aluminum drive caps, shall have composite metal and EPDM washers. Fasteners having integral hex washer heads or aluminum drive caps shall have EPDM washers. Side laps of roofing panels having configurations 3/4 inch deep or less shall be fastened at a maximum spacing of 12 inches on center. Heads of screws or bolts exposed on exterior face of factory-finished wall panels shall be nylon or shall be provided with plastic color caps to match color of panels.
2.1.15 Insulation: Provide blanket type .6-pound fiberglass having a factory applied facing on one side, except where two layers are used, the second layer shall be unfaced. The insulation shall conform to the NIA 404 standard. The insulation shall have a permeance rating of .05 or less when tested in accordance with ASTM E96. The facing on the insulation shall be vinyl- scrim foil. The vinyl-scrim foil facing shall have a tensile strength of not less than 40 pounds machine direction and 30 pounds cross machine direction when test in accordance with ASTM D828. The insulation shall conform to the ASTM 991 and NAIMA 202-96 standards. The insulation, including facings, shall have a flame spread rating of 25 or less and a smoke development factor of 50 or less when tested in accordance with ASTM E84. The minimum thermal resistance of the insulation shall be R13 for the walls + R13ci Insulated Metal Wall Panels, and R49 for the ceiling.
2.1.16 Doors and Windows: Doors and windows are specified in other sections. Provide framing members and flashings as necessary for installation of the doors and windows.
2.1.17 Cross Bracing: Shall be steel rod; cable is not acceptable. Provide portal frames where cross-bracing would interfere with openings.
2.1.18 Canopies: Of same materials and finish as the building.
2.1.19 Snow Fence (Rail) System: Aluminum, approximately 3 inches in height and continuous in length with attachments to metal roof panels. Provide 3 – rows along full length of eaves of building. Provide manufacturer approved shop drawings. Type: “SnoFence Metal Roof Snow Fence Guard” as manufactured by “S-5” (Or approved equal).
2.1.20 Gutters and Downspouts: Form from not less than 26 gauge sheet steel. Gutters shall be nominally 4-1/2 inches wide x 5 inches high. Provide die form stainless steel strap designed to be attached to the top of each standing seam at roof edge. Downspouts shall be nominally 5
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PREENGINEERED METAL BUILDINGS (RIGID FRAME)
inches wide x 4 inches deep. Terminate downspouts which discharge at grade with a 45 degree elbow. Terminate downspouts which discharge into an underdrain with a plastic transition piece matching the diameter of the underdrain.
2.1.21 Finish:
2.1.21.1 Shop Painting: Ferrous metal work, except factory-finished work, zinc-coated work, aluminum-coated work, and work specified to be painted herein, shall be (1) cleaned of dirt, rust, scale, loose particles, grease, oil, and other deleterious substances; (2) phosphate treated; and (3) then be given one coat of an approved rust-inhibiting primer paint of the type standard with the metal building manufacturer.
2.1.21.2 Factory Finishing: As indicated.
a. Enamel Finish: Interior exposed surfaces of metal roof and wall panels, liner panels, roof ventilators, louvers, gutters, downspouts, and metal accessories shall be provided with a baked-on, factory-applied enamel finish. The finish shall consist of cleaning, pretreatment, and one coat of baked-on silicone polyester finish applied to a dry film thickness of not less than 1.0 mil.
b. Organic Finish: Exterior exposed surfaces of metal roof and wall panels shall have a baked-on, factory-applied color coating of polyvinylidene fluoride (PVF2) or other equivalent fluorocarbon coating applied after metal substrates have been cleaned and pretreated. The finish coating dry-film thickness shall be 0.8 to 1.3 mils. Interior exposed surfaces shall receive baked-on enamel finish as specified herein.
2.1.22 Grouting Mortar: Specified in Section 03300, "Cast-In-Place Concrete".
PART 3 - EXECUTION
3.1 ERECTION: Erect in accordance with the manufacturer's approved erection instructions and diagrams, except as specified otherwise. Correct defects and errors in the fabrication of building components in a manner approved by the Engineer. If defects or errors in fabrication of components cannot be corrected, remove and provide non-defective components. Plumb, guy, and stay columns and rigid frames in both directions, and accurately space framing elements to ensure proper fit of prefabricated wall and roof panels. When installing wall and roof systems, install closure strips, flashing, sealing material, and other accessories in a manner approved by
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the Engineer so that the systems are weathertight, free of abrasions, loose fasteners, and deformations. After erection is complete, repair and coat abraded and damaged, primed or factory-finished surfaces to match adjacent surfaces.
3.1.1 Dissimilar Materials: Prevent direct contact between aluminum surfaces, and ferrous or other incompatible metals, by one of the following methods:
a. Paint the incompatible metal with a coating of heavy-bodied bituminous paint conforming to FS TT-C-520.
b. Paint the incompatible metal with a prime coat of corrosion inhibitive primer followed by one or two coats of aluminum metal-and-masonry paint, or other suitable protective coating, excluding products containing lead and chromium pigmentation.
c. Provide an approved nonabsorptive gasket.
d. Apply an approved caulking between the aluminum and the incompatible metal.
If drainage from incompatible metal passes over aluminum, paint the incompatible metal by method (a) or (b). Paint aluminum surfaces in contact with concrete or masonry materials by method (a). Paint green or wet wood, or wood treated with incompatible wood preservatives, by method (a) or use two coats of aluminum paint.
3.1.2 Rigid Frames, Bases, and Sill Members: Set accurately, using a nonshrinking grouting mortar to obtain uniform bearing on the concrete and to maintain a level base line elevation. Anchors and anchor bolts for securing rigid frames, columns, or sill members to foundations shall be unpainted steel, set accurately to templates, and of proper size to adequately resist applicable design loads at the base. Clean surfaces to receive the mortar and thoroughly moisten immediately before placement of mortar. Water cure exposed surfaces of mortar with wet burlap for 7 days.
3.1.3 Wall Construction: Apply panels with the ribs in a vertical position. Apply panels in the longest obtainable lengths. Seal side and end laps with the joint sealing material specified herein as recommended by the manufacturer. Flash or seal walls at the base, at the top, around windows, door frames, framed louvers, and other similar openings. Flashing will not be required where approved "self-flashing" panels are used. Minimum end laps for all types of panels shall be 2-1/2 inches. Minimum side laps for all types of panels shall be one corrugation, one rib, or an interlocking joint. Provide liner panels from finished floor to eave.
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3.1.4 Roof Construction: Install clips and thermal blocks. Apply roofing panels with the ribs parallel to the slope of the roof. Apply the roofing panels in the longest lengths obtainable with end laps occurring only at structural members with no transverse joints except at the junction of ventilators, curbs, light transmitting roof panels, and similar openings. Lay side laps away from the prevailing wind, and seal side and end laps with joint sealing material. Flash and seal the roof at the ridge, at eaves and rakes, at projections through the roof, and elsewhere as necessary. Minimum side lap shall be interlocking rib. End laps shall not be less than 6 inches and shall occur only over purlins. Provide liner panels from ridge to eaves
3.1.5 Installation of Insulation:
3.1.5.1 Roof Insulation: Install over purlins before roof coverings are applied. Install roof insulation by draping faced layer loosely over purlins to form a cavity for the second unfaced layer. Install the second layer parallel to the purlins. Hold insulation rigid until secured in place. Insulation facing shall be exposed on the interior side of the building. Fold and staple facing tabs of insulation on 6-inch centers to completely seal joints. If folding and stapling is accomplished from the inside, push the tabs neatly up between the edges of adjoining blankets. Cover side laps of insulation with metal strips formed for this purpose and paint to match the facing material. Install the strips spanning from purlin to purlin and in accordance with the metal building manufacturer's recommendations.
3.1.5.2 Wall Insulation: Install over girts before wall coverings are applied. Hold insulation rigid until secured in place. Expose facing toward the interior side of the building. Fold and staple facing tabs of insulation on 6-inch centers to completely seal joints. If folding and stapling is accomplished from the inside, push the tabs neatly up between the edges of adjoining blankets. Cover side laps of insulation with metal strips formed for this purpose and paint to match the facing material. Install the strips spanning from girt to girt and in accordance with the metal building manufacturer's recommendations.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - PREENGINEERED METAL BUILDING (RIGID FRAME):
4.1.1 Measurement for Preengineered Metal Building (Rigid Frame) shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
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4.2 PAYMENT - PREENGINEERED METAL BUILDING (RIGID FRAME):
4.2.1 For Preengineered Metal Buildings (Rigid Frame), not included in other unit or lump sum price items, payment for Preengineered Metal Buildings (Rigid Frame) will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 13121-14 394.107.001 SECTION 13440
GLASS-COATED BOLTED STEEL LEACHATE STORAGE TANKS, TANK FLOORS, ROOFS AND APPURTENANCES
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this section the Contractor shall provide all required labor, materials and equipment for furnishing and erecting two, 1,125,000 Glass-Fused-to-Steel Leachate Storage Tanks, constructed of factory prefabricated glass-coated, bolt-together steel panels. Each tank structure shall include a foundation, floor, roof and other accessory components as shown on the Contract Drawings and described herein. Note that painted, powder coat, stainless steel or galvanized bolt-together tanks are not acceptable. Final exterior panel colors will be determined by the Owner.
1.1.2 All required tank materials and principal appurtenances shall be supplied by the tank manufacturer. Tank structures and appurtenances shall be new and not previously used.
1.1.3 Tanks shall be designed and produced in the United States of America, by a manufacturer specializing in the production of glass-coated, bolt-together steel tank systems. All structural steel utilized in the tank structure shall be produced and glass coated in the United States of America.
1.1.4 The tank manufacturer shall provide documentation upon request, including mill reports and traceable documents to demonstrate the source of steel used in the manufacture of this project specific tank.
1.1.5 The Engineer shall furnish the tank manufacturer with detailed information concerning the type and quality of materials to be stored. The information provided shall consist of, but not be limited to, specific gravity, PH, temperatures, conductivity and any chemical analysis/contaminants of the liquid.
1.1.6 For Glass-Coated Bolted Steel Leachate Storage Tank, work shall include, but not be limited to, the following items specified in other sections and all other work necessary for a complete and functioning installation as shown on the Plans, specified and/or directed:
a. Section 02072 Geotextile b. Section 02220 Excavation c. Section 02222 Granular Fill d. Section 02226 Select Fill Materials e. Section 02256 Common Fill Material f. Section 02258 Structural Fill Material
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g. Section 02596 High Density Polyethylene (HDPE) Lining Material h. Section 03210 Reinforcing Steel i. Section 03300 Cast-In-Place Concrete
1.2 REFERENCES: Publications by the entities listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American Society for Testing and Materials (ASTM) Publications:
A36/A36M Standard Specification for Carbon Structural Steel
A992/A992M Standard Specification for Structural Steel Shapes
A1011/A1011M Standard Specification for Steel, Sheet and Strip, Hot Rolled, Carbon, Structural, High-Strength Low-Alloy, High-Strength Low-Alloy with Improved Formability, and Ultra-High Strength
B916 Standard Test Method for Adherence of Porcelain Enamel Coatings to Sheet Metal
C633-79 Standard Test Method for Adhesion or Cohesion Strength of Flame-Sprayed Coatings
1.2.2 American Water Works Association (AWWA) Publications:
C652 Standard for Disinfection of Water-Storage Facilities
D100 Standard for Welded Steel Tanks for Water Storage
D103 Standard for Factory-Coated Bolted Steel Tanks for Water Storage
1.2.3 American Welding Society AWS D1.2/D1.2M – Structural Welding Code – Aluminum.
1.2.4 Federal Specification FS TT-S-00230C – Sealing Compound: Elastomeric Type, Single Component (For Calking, Sealing, and Glazing in Buildings and Other Structures).
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GLASS-COATED BOLTED STEEL LEACHATE STORAGE TANKS, TANK FLOORS, ROOFS AND APPURTENANCES
1.2.5 General Services Administration Commercial Item Description GSA CID A-A- 59588A – Rubber, Silicone.
1.2.6 Society for Protective Coatings SSPC-SP 10/NACE No. 2 – Surface Preparation Standard - Near White Metal Blast Cleaning.
1.2.7 Society of Automotive Engineers (SAE).
1.2.8 SAE J429 – Mechanical and Material Requirements for Externally Threaded Fasteners.
1.2.9 International Organization for Standardization (ISO) Publications:
28706-1:2008 Vitreous and Porcelain Enamels - Determination of Resistance to Chemical Corrosion
2859 Sampling Procedures for Inspection by Attributes
6370-2 Vitreous and Porcelain Enamels – Determination of Resistance to Abrasion
1.3 QUALITY ASSURANCE:
1.3.1 ANSI/AWWA D103-09: Tank steel panel materials, design, fabrication and erection shall conform to all pertinent sections of the AWWA Standard for Bolted Steel Tanks unless otherwise specified herein.
1.3.1.1 Tank structural design shall conform to AISC Specifications.
1.3.2 Factory Mutual (FM): Certification of annual review of quality control procedures of the manufacturing plant by FM.
1.3.3 IBC Design: Tanks will be designed such that Seismic, Wind and Roof designs conform to the current state and local standards.
1.3.4 ISO 9001: The tank manufacturer’s Quality Assurance program shall be certified to comply with ISO 9001 standards.
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GLASS-COATED BOLTED STEEL LEACHATE STORAGE TANKS, TANK FLOORS, ROOFS AND APPURTENANCES
1.4 BIDDING QUALIFICATIONS:
1.4.1 Tank will be supplied by Statewide Aquastore, Inc. located in East Syracuse, New York. Tank manufacturer will be CST Storage of DeKalb, IL, or pre-approved alternate. No other manufacturer will be acceptable.
1.4.2 The Engineer’s selection of factory applied glass-fused-to-steel bolt together tank construction for this project has been predicated upon specific criteria, construction methods, and an optimum coating resistance to internal and external tank corrosion. Deviations from the specified design, construction or coating details will not be permitted.
1.4.3 The Contractor MUST submit a site and project specific foundation designed by the tank manufacturer, with the applicable state PE stamp. No third party designs will be allowed. The (Contractor/authorized dealer) tank manufacturer shall be solely responsible for the tank structural steel and foundation design.
1.4.4 The Engineer/Owner reserves the right to evaluate all alternatives based on long term, 30-40 year minimum operation, coating and maintenance costs. Values to be used in this evaluation will be at the discretion of the Engineer to determine which tank best fits the Owner’s needs.
1.4.4.1 Tank Manufacturer:
a. The tank manufacturer shall be a specialist in the design and fabrication with a minimum of 15 years documented experience in the United States in similar climates, sizes and applications. The tank manufacturer shall employ a staff of full time design Engineers, and shall own and operate its steel fabrication and glass coating facilities.
b. Naming of a manufacturer does not relieve them from complying with the performance features, the salient features and any Made in the USA requirements of the Contract Documents. The Contract Documents represent the minimum acceptable standards that will be allowed.
c. In order to assure uniform quality and ease of maintenance, it is the intent of these specifications that all equipment under this section shall be supplied by a single manufacturer and that the equipment manufacturer and installation Contractor assume the responsibility for proper installation and functioning of equipment.
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d. Manufacturers and/or tank providers lacking the experience requirements listed in this section or elsewhere in the Contract Documents will NOT be considered without prior approval. Strict adherence to the standards of design, fabrication, erection, product quality, and long-term performance established in this Specification will be required by the Engineer and Owner.
1.4.4.2 Tank Provider:
a. An authorized dealer of the tank manufacturer shall provide and install the tank. Subcontracting of the tank erection by the dealer shall not be permitted. Building crews shall comply with the tank manufacturer’s requirements for building practices and equipment used on the job.
b. Employees of the authorized dealer shall be experienced in the construction of the specified tank and should be trained in a factory training program receiving builder certification by the tank manufacturer, and shall be employed full time by the authorized dealer.
c. The tank provider/builder shall have built, on its own, at least 30 tanks of similar type that are equal or greater in size than the specified tank, operating satisfactorily for a minimum of (15) fifteen years and shall provide with bid the reference name, location, application and year of supply/operation of the tank. Tank manufacturer and tank provider shall each provide with bid the reference name, address and telephone number of the responsible representative, application and year of supply/operation of the above referenced liquid tanks installed in the United States. List should indicate the specific application.
d. Builders lacking the experience requirement will not be considered.
1.4.4.3 Substitute/Alternate/or Equal – Pre-approval:
a. Substitute/Alternate/or equal bids will only be considered with prior approval by the Engineer. This requirement is intended to protect the Owner so that no one Bidder gains an unfair price advantage by quoting a lesser product that does not comply with the minimum performance and salient features set forth in these Specifications.
b. All requests must be made at least 10 business days prior to the specified bid date or they will not be considered. Only bids from tank suppliers/builders who have successfully prequalified will be considered.
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c. If Bidder fails to prequalify and provide the documentation deemed necessary by the Engineer to evaluate a proposed substitute or “or equal” equipment, the proposed tank will be rejected. The Engineer is the sole authority for determining conformance to the Specifications and whether to pre-qualify a proposed supplier. Under no circumstances will they be required to prove that an alternate product is not equal to the specified equipment. The Engineer’s decision or judgment on these matters will be final, conclusive and binding.
d. Tank suppliers looking to pre-qualify shall provide a copy of this Specification with a check mark next to each item where the proposed equipment does not adhere to the specification, provide information on the exception and how the proposed equipment would be brought into adherence with the item required.
e. Site specific, applicable State PE stamped tank foundation and general arrangement drawings with full dimensions and a list of all appurtenances proposed. Include also a tabulation of the number of steel sheets in each tank ring, and the number of rings, the sheet thickness, the ASTM Grade, and the maximum allowable tensile stress for each ring.
f. A description of surface preparation for steel sheets prior to glass coating, including cleaning. Describe pre-coating and glassing procedures, and indicate maximum and minimum glass coating thickness anticipated. Outline inspection, handling and packaging procedures to assure a quality product. Document three coat coating application. Outline inspection, handling and packaging procedures to assure a quality product.
g. A list of a minimum 30 installations in North America with a record of satisfactory service, presently in leachate storage service designed to AWWA D103 standards, in projects of similar magnitude, in similar climates, for a period of not less than fifteen (15) years, which have been manufactured in the present production facility and installed by the tank erector/provider. List dates of completion and name, address and telephone number of the responsible representative of the Owner and/or the Engineer.
h. A tank assembly guide, prepared by the tank manufacturer to familiarize the Engineer and inspector with basic building procedures. As a minimum, the guide shall include: safety guidelines; building tools, equipment, and material; footing and foundation construction; floor construction; tank wall construction; roof installation; appurtenance installation.
2.19 13440-6 394.107.001 SECTION 13440
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i. Representative sample of “edge coating” and “glass coating” used on the proposed tank.
1.5 SUBMITTALS:
1.5.1 Before executing any work in this Section, the tank manufacturer shall submit for documentation, job specific structural calculations for tank and foundation, general arrangement drawings and specifications for the tank structure, foundation, joint sealant and all appurtenances. Documentation above shall be sealed by a Professional Engineer licensed and registered in the applicable state. Evidence of professional liability insurance shall be provided, if requested.
1.5.2 Submittals shall include certification that each applicable Section of AWWA D103 is met. Any exceptions taken shall be noted with full explanation given for the deviation. Provide a copy of this Specification with a check mark next to each item where the proposed equipment does not adhere to the specification, provide information on the exception and how the proposed equipment would be brought into adherence with the item required.
1.5.3 Copy of Builder Certification Program, sponsored by the tank manufacturer, certifying factory training and experience of the proposed builder.
1.5.4 The tank manufacturer shall provide a standard Operation and Maintenance Manual upon approval of the drawings and completion of the tank installation.
1.5.5 All engineering costs which cause changes in design from the Plans and Specifications are to be borne entirely and unconditionally by the Contractor. Due to the long lead time for the tank, the shop drawings shall be submitted within 15 days following the issued Notice of Award.
1.5.6 Submit documentation certifying tank design and manufacture in the United States. Submit documentation certifying steel produced and glass coated in United States.
1.5.7 Qualifications of Tank Builders supervisory personnel shall be submitted for review. Personnel shall have experience in construction of at least ten years in bolted glass fused to steel construction. Construction experience shall be for tanks of similar size as to the one specified herein.
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1.5.8 Provide Engineer with any subcontractors to be used on the project. Owner reserves the right to reject without penalty any subcontractor that he feels is not capable of performing the work. Submittal shall include names of persons to be used on the project, experience, and three references for similar type of work.
1.5.9 Provide Engineer with name of proposed construction foreman to be used on the project, with resume documenting experience with at least (3) prior tank construction projects that are fully complete. Owner reserves the right to reject without penalty proposed foreman that does not meet the prior experience requirements.
1.6 WARRANTY:
1.6.1 If within a period of one (1) year from date of substantial completion or the start of operation, the tank structure or any part thereof shall prove to be defective in material or workmanship upon examination by the manufacturer, the manufacturer will supply a replacement part, will repair, or allow a credit for same.
1.6.2 The warranty shall be further extended with the use of a manufacturer supplied cathodic protection system as follows: the glass coated product zone surfaces, that portion of the tank interior below the normal high elevation of the contained liquid will not corrode under normal and proper use, maintenance and operation during the period expiring on the earlier of (i) 60 months after liquid is first introduced into the tank.
PART 2 - PRODUCTS
2.1 GENERAL: Tank structures shall be of vertical, cylindrical, flat bottom glass-coated, bolt-together steel construction. Epoxy, powder coated, galvanized or stainless steel are not considered equal and will not be considered.
2.2 DESIGN:
2.2.1 Tank shall be in 100% adherence to US, State and local codes, standards and requirements. No foreign designs or codes will be accepted. 2.2.2 The factory coated glass-fused-to-steel; bolt together tank shall have a nominal diameter of 81.13 feet, with a nominal sidewall height of 29.10 feet.
2.2.3 Tank capacity shall be 1,125,000 gallons (nominal, U.S. gallons) and match the existing tank currently in operation.
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GLASS-COATED BOLTED STEEL LEACHATE STORAGE TANKS, TANK FLOORS, ROOFS AND APPURTENANCES
2.2.4 Finished floor elevation shall be set to exactly match the existing adjacent tank in- place.
2.3 DESIGN CRITERIA: Loads to be considered in the tank and roof design shall include basic live, seismic and snow loads.
2.3.1 Specific Gravity: (Minimum design shall be 1.0).
2.3.2 Design Freeboard: 24 inches, match existing tank.
2.3.3 Net allowable soil bearing capacity 2,000 PSF.
2.3.4 Seismic Design:
a. Design per NYSBC 2010 b. Map Spectral Response i. Ss .233 ii. S1 .071 c. Importance Factor based on Category XXX (IE) (Category III) e. Site Class D f. Long Period Transition Period 6 Seconds (TL)
2.3.5 Snow Load:
a. Ground Snow Load 62 PSF b. Importance Factor 1.1 (Is) c. Thermal Factor 1.2 (Ct) d. Exposure Factor 1.0 (Ce)
2.3.6 Wind Load (per AISC):
a. Basic Wind Speed 90 mph b. Importance Factor 1.15 (IW) c. Exposure Category C
2.3.7 Frost depth 80”.
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2.3.8 Load cases (include the self weight of the structure in all of the following load combinations) shall be analyzed to determine the controlling stresses, as follows:
a. Normal operating conditions (full tank) with a full snow load. b. Empty tank, no snow. c. Wind, or earthquake, on empty tank, full snow. d. Wind, or earthquake, on empty tank, snow on leeward side of dome. e. Wind, or earthquake, on empty tank, no snow
2.4 PLATES AND SHEETS:
2.4.1 Plates and sheets used in the construction of the tank shell, floor, or roof shall comply with the minimum standards of AWWA D103, latest edition. All steel shall be smelted and produced in the United States of America.
2.4.2 The annealing effect created from the glass coated firing process shall be considered in determining ultimate steel strength. In no event shall a yield strength greater than 50,000 psi be utilized for calculations detailed in AWWA D103, latest revision.
2.4.3 Design requirements for mild strength steel shall be ASTM A-1011 Grade 30 with a maximum allowable tensile stress of 14,566 psi. High strength steel shall be ASTM A-1011 Grade 50 with a maximum allowable tensile stress of 26,000 psi.
2.4.4 When multiple vertical bolt line sheets and plates of ASTM A-1011 Grade 50 are used, the effective net section area shall not be taken as greater than 85% of the gross area.
2.4.5 When rolled structural shapes are used, the material shall conform to minimum standards of ASTM A36 or ASTM A992.
2.4.6 Chemical compositions for mild steel and high strength steel shall be stated in the submitted mill certifications. Raw steel for plates and sheets shall conform to the following composition requirements. These Specifications refer to the design tensile strength after firing. The steel shall have the following chemical composition:
a. Carbon (Mild) 0.06% maximum b. Carbon (HSS) 0.10% maximum c. Manganese 1.50% maximum d. Phosphorus 0.04% maximum e. Sulfur 0.05% maximum f. Aluminum 0.08% maximum 2.19 13440-10 394.107.001 SECTION 13440
GLASS-COATED BOLTED STEEL LEACHATE STORAGE TANKS, TANK FLOORS, ROOFS AND APPURTENANCES
2.5 HORIZONTAL WIND STIFFENERS:
2.5.1 Stiffeners shall be of the "web truss" design, with extended tail to create multiple layers of stiffener, fabricated of steel with hot dipped galvanized coating. Rolled angle stiffeners shall not be permitted for intermediate horizontal wind stiffeners.
2.6 BOLT FASTENERS:
2.6.1 Bolts used in tank lap joints shall be 1/2-13 UNC-2A rolled thread and shall meet the minimum requirements of AWWA D103, latest revision. Bolt material shall be SAE J429 Grade 2 (1” bolt length) with a tensile strength of 74,000-psi minimum, and a proof load of 55,000-psi min. and an allowable shear stress with threads excluded from the shear plane of 18,163-psi min.
2.6.2 SAE J429 Grade 5/ASTM A325 (1-1/4” bolt length) and heat treated to a tensile strength of 120,000 psi min and a proof load of 85,000 psi min. and having an allowable shear stress with threads excluded from the shear plane of 29,454 psi min.
2.6.3 SAE J429 Grade 8/ASTM A490 (bolts greater than 1-1/4”) and heat treated to a tensile strength of 150,000 psi min and a proof load of 120,000 psi min. and having an allowable shear stress with threads excluded from the shear plane of 36,818 psi min.
2.6.4 The bolt finish shall be Zinc, mechanically deposited.
2.6.5 The entire bolt head shall be encapsulated up to the splines on the shank with high impact polypropylene copolymer. Resin shall be stabilized with an ultraviolet light resistant material such that the color shall appear black. The bolt head encapsulation shall be certified to meet the ANSI/NSF Standard 61 for indirect additives.
2.6.6 All lap joint bolts shall be properly selected such that threaded portions will not be exposed in the "shear plane" between the sheets. In addition, bolt lengths shall be sized as to achieve a neat and uniform appearance. Excessive threads extending beyond the nut will not be permitted.
2.6.7 All lap joint bolts shall include a minimum of four (4) splines, on the underside of the bolt head at the shank in order to resist rotation during torque wrench application.
2.7 SEALANTS: Selection of sealant will be determined by actual liquid via chemical analysis provided by the Engineer/Owner.
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GLASS-COATED BOLTED STEEL LEACHATE STORAGE TANKS, TANK FLOORS, ROOFS AND APPURTENANCES
2.7.1 The lap joint sealant shall be a one component, moisture cured, polyurethane compound. The sealant shall meet applicable FDA Title 21 regulations, and be manufactured by a United States supplier. The sealant shall be used to seal lap joints, bolt connections and sheet edges. The sealant shall be CST Storage, Manus Sealer No. 98. The sealant should have a curing rate at 73°F and 50% RH and be tack free in 6 to 8 hours. Final cure time should be 10 to 12 days. Neoprene gaskets and tape type sealer shall not be used.
2.7.2 The sealant shall cure to a rubber like consistency, have excellent adhesion to the glass coating, low shrinkage and be suitable for interior and exterior use.
2.8 GLASS COATING PROCESS:
2.8.1 The glass coating system shall be in full accordance with the requirements of AWWA D103, latest revision. Every batch of coating frits shall be individually tested in accordance with PE1 Test T-21. (Citric acid at room temperature.)
2.8.2 Surface Preparation: Following the de-coiling and shearing process, sheets shall be steel grit blasted on both sides to the equivalent of SSPC PC-10 (near white metal blast cleaning). Sandblasting and chemical pickling of steel sheets is not acceptable. The surface anchor pattern shall be not less than 1.0 mils. (.0001 inches). Sheets shall be evenly oiled on both sides to protect them from corrosion during fabrication.
2.8.3 Cleaning: After fabrication and prior to application of the coating system, all sheets shall be thoroughly cleaned by caustic wash and hot water rinse followed immediately by hot air drying. Inspection of the sheets shall be made for traces of foreign matter, soil particles, grease or rust. Any such sheets shall be re-cleaned or grit-blasted to an acceptable level of quality.
2.8.4 Coating Application: All sidewall sheets shall receive one coat of a catalytic nickel oxide glass pre-coat to both sides, followed by air-drying.
2.8.4.1 A second coat of milled cobalt blue glass shall be made to both sides of the sheets and then dried.
2.8.4.2 A third cover coat of milled titanium dioxide white glass shall then be applied to the inside of the sheet and the sheet edges. This milled glass shall be formulated with titanium dioxide to produce a finish interior surface with optimum toughness and resistance to conditions normally found in leachate storage tanks. This specific coating shall be Aquastore Vitrium. Any alternate three coat system must be submitted for approval and acceptance prior to Bid.
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GLASS-COATED BOLTED STEEL LEACHATE STORAGE TANKS, TANK FLOORS, ROOFS AND APPURTENANCES
2.8.4.3 The sheets shall then be fired at a minimum temperature of 1500 °F in strict accordance with ISO 9001 quality process control procedures, including firing time, furnace humidity, temperature control, etc.
2.8.4.4 The dry film interior coating thickness shall be 10-18 mils min. The dry film exterior coating thickness shall be 7-15 mils min. This is a three coating process. The finished tank inside sidewall glass coating shall be white. The standard tank sidewall finished outside color shall be Cobalt Blue. (Munsell standard 7.5 PB 2/4.) Finished outside colors shall not vary noticeably among tank panels. Off color panels will be rejected; replacement panels of matching color shall be supplied by the tank manufacturer.
2.8.5 Sheet Edge Coating: After initial sheet preparation, all four (4) exposed continuous edges of full height vertical wall sheets and all rectangular shaped floor sheets shall be mechanically beveled and coated with a 316 stainless steel corrosion resistant alloy using an ARC thermal spray and shall be thermally bonded on these edges at a thickness of 1.5 to 5 mils prior to the glass coating of the sheet edges. Hand grinding of the sheet edges is not allowed. All exposed sheet edges will then be coated the same as the glass coating of the sheets. The process shall be equal to the Edge Coat™ by CST Storage. Sealer or glass overspray as edge coating shall not be acceptable. The coating shall have a tensile strength of 1500 psi.
2.9 INSPECTION:
2.9.1 The manufacturers quality system shall be ISO 9001 certified and refer to ISO (International Organization of Standardization) for the following testing and procedures. All coated sheets shall be inspected for mil thickness using an electronic dry film thickness gage with a valid calibration record. Test frequency shall be every tenth sheet and shall measure thicknesses of glass as designed.
2.9.2 All sheets shall be measured for color using an electronic colorimeter with a valid calibration record. Test frequency shall be every tenth sheet and the color must fall within the specified tolerance or it shall be rejected.
2.9.3 An electrical leak detection test shall be performed on the inside surface of each panel after fabrication. Inside wet sheet surfaces shall be inspected using a low voltage wet sponge holiday tester in accordance with ASTM D5162-91 Method A. HVST testing is not acceptable. The tester shall be used at a voltage of 67.5 volts (+/- 10 %) and set so the alarm is sounded if the electrical resistance of the glass coating falls below 125,000. The tester shall have a valid
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GLASS-COATED BOLTED STEEL LEACHATE STORAGE TANKS, TANK FLOORS, ROOFS AND APPURTENANCES
calibration record. The testing solution used to wet the sponge shall contain a low suds wetting agent added at a ratio of not more than ½ fluid oz. per gallon of water. Every sheet shall be 100% tested for holidays and any sheet with a discontinuity shall be rejected.
2.9.4 All inside sheet surfaces shall be holiday free. A dry volt test using a minimum of 1100 volts may be used. Frequency of the test shall be every sheet. Any sheet registering a discontinuity on the interior surface shall be rejected
2.9.5 Adherence of the glass coating to the tank steel shall be tested in accordance with ISO standards. Any sheet that has poor adherence will be rejected. The minimum frequency of testing for this shall be one sheet per gage lot run.
2.9.6 Glass coating shall be tested for fishscale by placing the full size production sheets in an oven 400°F for one hour. The sheets will then be examined for signs of fishscale. Any sheet exhibiting fishscale shall be rejected and all sheets from that gage lot will be similarly tested. The minimum frequency of testing for this shall be one sheet per gage lot run.
2.9.7 Engineer shall be provided the results of all of the above tests upon request.
2.10 FLOORS:
2.10.1 The tank floor shall be constructed either of glass-coated steel panels or of reinforced concrete as shown on Contract Drawings. If fill is used, the fill under the floor/footing shall be compacted and tested to a minimum of 95% of proctor.
2.10.1.1 Glass Floor: The glass-coated steel floor panels shall have the same milled glass, formulated with titanium dioxide, as the tank sidewalls to produce a finish interior surface with optimum toughness and resistance to conditions normally found in leachate storage tanks. The finished tank interior floor glass coating shall be white.
2.11 ROOFS:
2.11.1 Tank roof shall be furnished by the tank manufacturer and be constructed of triangular aluminum panels as shown on contract drawings.
2.11.2 Roofs shall be clear span and self-supporting. Center post supports are not permitted. Roof live loads and dead loads shall be carried by tank sidewalls, without additional support. A roof hatch, with a hinged gasketed cover and locking hasp, shall be provided near the outside tank ladder.
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GLASS-COATED BOLTED STEEL LEACHATE STORAGE TANKS, TANK FLOORS, ROOFS AND APPURTENANCES
2.11.3 Roofs shall be manufactured and supplied from the same manufacturer as the tank.
2.12 ALUMINUM DOME ROOFS:
a. Aluminum dome roofs are aluminum in color and shall be constructed of non- corrugated, triangular aluminum panels, which are sealed and firmly clamped in an interlocking manner within a fully triangulated aluminum space truss system of wide flange extrusions, thus forming a dome structure. They shall be supplied by CST Storage only, the tank manufacturer. Fabric type flashing is not allowed.
b. The dome shall be self supporting from the periphery structure with horizontal thrust contained by an integral tension ring.
c. The walkway and handrail if supplied shall be constructed of aluminum.
d. The roof manway opening shall be at least 30” square. The opening shall have a curb of at least 4” in height, and the cover shall have a downward overlap of at least 2”. The manway shall be aluminum.
e. Dome Materials:
i. Triangulated dome frame struts: 6061-T6 aluminum. ii. Structural frame gussets: 6061-T6 aluminum, 0.375 inch nominal thickness. iii. Triangular closure panels: .050 inch nominal thickness, 3003-H16 aluminum Sheet. iv. Triangular skylight panels, (if specified): ¼ inch thick clear acrylic. Skylight square footage shall be v. 1% of covered area, minimum. vi. Perimeter tension/compression ring: 6061-T6 aluminum. vii. Fasteners: 7075-T73 anodized aluminum or Series 300 stainless steel. viii. Sealant: Silicone by Pecora, General Electric Silpruf or equal. ix. Gaskets: Silicone, General Electric SE-44/88 or equal. x. Anchor Fasteners: Series 300 stainless steel. xi. Dormers, doors, and hatches: 6061-T6, 5086-H34 or 5052-H36 aluminum, 0.090inch nominal thickness.
f. The roof supplier shall perform all manufacturing work described herein with mechanics skilled and experienced in the fabrication of aluminum dome roof structures. Fabrication shall be done in an ISO 9001 certified facility.
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g. All field work shall be completed by the tank manufacturers/provided qualified erection crew. Sub-contracting of the roof erection is not allowed.
h. Field re-fabrication of structural components or panels will not be accepted. Forcing of the structure to achieve fit-up during construction is expressly forbidden and not acceptable. Any indication of improper fit-up of parts shall be immediately reported to the fabricator.
i. All sealant joints shall be tooled slightly concave after sealant is installed. Care shall be taken to keep sealant confined to the joint in a neat manner. Any sealant applied outside of the joint shall be removed so that the panels will be free from misplaced sealant. All gasket materials shall be continuous, splices will not be allowed.
2.12 APPURTENANCES:
2.12.1 Pipe Connections: Where pipe connections are shown to pass through tank panels, they shall be field located, saw cut, (acetylene torch cutting or welding is not permitted), and utilize an interior and exterior flange assembly. Tank shell reinforcing shall comply with AWWA D103 latest edition. CST Storage Sealer No. 98 shall be applied on any cut panel edges or bolt connections.
2.12.2 Overflow piping shall HDPE SDR 17 piping. Provide twenty four mesh non corrodible screen. Install within the pipe location least susceptible to damage. Provide two overflow pipes per tank.
2.12.3 Outside Tank Ladder: An outside tank ladder shall be furnished and installed as shown on the Contract Drawings. Ladders shall be aluminum and utilize grooved, skid-resistant rungs.
2.12.4 Safety cage and step-off platforms shall be fabricated of galvanized steel. Ladders shall be equipped with a hinged lockable entry device.
2.12.5 Access Doors: Each tank shall be provided with one (1) 24-inch diameter bottom access door as shown on Contract Drawings per AWWA D103. The manhole opening shall be a minimum of 24 inches in diameter. The access door and tank shell reinforcing shall comply with AWWA D103 latest edition. A davit to hold the cover plate is required.
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GLASS-COATED BOLTED STEEL LEACHATE STORAGE TANKS, TANK FLOORS, ROOFS AND APPURTENANCES
2.12.6 Identification Plate: A manufacturers nameplate shall list the tank serial number, tank diameter and height, maximum design capacity, intended storage use, and date of installation. The nameplate shall be affixed to the tank exterior sidewall at a location approximately 5' from grade elevation in a position of unobstructed view.
2.12.7 Cathodic Protection System: The tank manufacturer will provide a cathodic protection system designed specifically for the project tank, consisting of sacrificial anodes which provide protection for the portion of the structure immersed in liquid. The anodes are attached to the floor, and bolted through existing shell sheet bolt holes. Lead wires and buss bars are used to ensure continuity between anodes and all structure shell sheets.
2.12.8 The cathodic protection system shall be designed by a Licensed Professional Engineer employed by the tank manufacturer. The system shall be designed to protect both the tank and the foundation rebar in concrete floors.
2.13 PACKAGING:
2.13.1 All sheets that pass Factory Inspection and Quality Control checks shall be protected from damage prior to packing for shipment.
2.13.2 Heavy paper or plastic foam sheets shall be placed between each panel to eliminate sheet-to-sheet abrasion during shipment.
2.13.3 Individual stacks of panels will be wrapped in heavy mil black plastic and steel banded to special wood pallets built to the roll-radius of the tank panels. Shipment from the factory shall be by truck, exclusively hauling the tank components. This procedure minimizes contact or movement of finished panels during shipment.
PART 3 - EXECUTION
3.1 GENERAL: Supervisory personnel of the erection crew shall identify themselves to responsible personnel of the Engineer or Inspector upon initially entering the job site. Only trained and certified personnel will be allowed on site.
3.2 TANK FOUNDATION:
3.2.1 The tank foundation shall be built in accordance with the Contract Drawings and/or approved shop drawings and shall be designed by the Licensed Engineer or manufacturer to
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GLASS-COATED BOLTED STEEL LEACHATE STORAGE TANKS, TANK FLOORS, ROOFS AND APPURTENANCES
safely sustain the structure and its live loads. Only embedded starter ring designs are acceptable for concrete floors. Slot mount foundations will not be allowed.
3.2.2 Leveling of the starter ring shall be required and the maximum differential elevation with the ring shall not exceed 1/8 inch, nor exceed 1/16 inch within any 10 feet of circumference.
3.2.3 In no case shall the backfill elevation vary more than one (1) foot around the periphery of the tank shell.
3.2.4 A leveling plate assembly, consisting of two anchor rods and a slotted plate shall be used to secure the starter ring, prior to encasement in concrete. Installation of the starter ring on concrete blocks or bricks, using shims for adjustment, is not permitted.
3.2.5 Place one butyl rubber elastomeric waterstop seal on the inside surface of the starter ring below the concrete floor line. Place one bentonite impregnated water seal below the butyl rubber seal. Install materials in accordance with CST Storage instructions.
3.3 FLOORS:
3.3.1 Glass-coated bolted steel floor panels shall be assembled over a 3 inch compacted sand base contained by either a steel grade band or concrete ring wall. Alternately, if the panels are to be set on a concrete slab, a non-extruding and resilient bituminous type of filler may be used, meeting the requirements of ASTM D1751.
3.3.2 Plastic encapsulated nuts shall be used to cover the bolt threads exposed on the inside of the floor. The plastic encapsulation shall be Noryl GFN2-701S and NSF compliant.
3.4 TANK STRUCTURE:
3.4.1 Field erection of the glass-coated, bolted-steel structures and components shall be in strict accordance with the procedures established by manufacturer and performed by an authorized dealer only of the tank manufacturer regularly engaged in erection of these tanks, using factory-trained certified erectors fully employed by the Dealer.
3.4.2 Vertical tank seams shall be offset. Straight seam 4 corner joints are not acceptable.
3.4.3 Only specialized erection jacks and building equipment developed and supplied by the tank manufacturer shall be used to erect the tanks.
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3.4.4 Particular care shall be taken in handling and bolting of the glass-coated steel tank panels, appurtenances and members to avoid abrasion of the coating system. Prior to liquid test, all surface areas shall be visually inspected. Chips or scrapes in the glass coating shall be repaired per the tank manufacturer's recommended procedure.
3.4.5 An electrical leak test shall be performed during erection using a wet sponge nine-volt leak detection device. All electrical leak points found on the inside surface shall be repaired in accordance with manufacturers published touch-up procedures.
3.4.6 No backfill is to be placed against the tank sidewall without prior written approval of the tank manufacturer. Any backfill allowed shall be placed strictly in accordance with the instructions of the tank manufacturer.
3.5 FIELD TESTING:
3.5.1 Following completion of erection and cleaning of the tank, the structure shall be tested for liquid tightness by filling to its overflow elevation for a 24 hour period.
3.5.2 Any leaks disclosed by this test shall be corrected by the authorized dealer in accordance with the manufacturer's recommendations.
3.5.3 Water required for testing will be furnished and disposed of by the Contractor following completion of tank erection. Labor and equipment necessary for hydrostatic tank testing shall be included in the contract price of the tank.
3.6 INSPECTION:
3.6.1 On or near the (1) year anniversary date of initial tank the manufacturer's authorized dealer shall make a visual inspection of the tank interior coating and appurtenances, tank exterior coating and appurtenances, and the immediate area surrounding the tank for evidence of leakage. A written summary of the inspection report will be filed with the tank owner and the tank manufacturer.
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PART 4 – MEASUREMENT & PAYMENT
4.1 MEASUREMENT – GLASS-COATED BOLTED STEEL LEACHATE STORAGE TANKS, TANK FLOORS, ROOFS AND APPURTENANCES:
4.1.1 Measurement for Glass-Coated Bolted Steel Leachate Storage Tanks, Tank Floors, Roofs and Appurtenances shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT – GLASS-COATED BOLTED STEEL LEACHATE STORAGE TANKS, TANK FLOORS, ROOFS AND APPURTENANCES:
4.2.1 For Glass-Coated Bolted Steel Leachate Storage Tanks, Tank Floors, Roofs and Appurtenances, not included in other unit or lump sum price items, payment for Glass-Coated Bolted Steel Leachate Storage Tanks, Tank Floors, Roofs and Appurtenances will be made at the applicable price stated in the Bid. The Owner shall retain 10 percent of the price of the glass- coated bolted steel leachate storage tanks, tank floors, roofs and appurtenances until the Contractor provides acceptable warranty and the leakage testing has been successfully completed.
END OF SECTION
2.19 13440-20 394.107.001 SECTION 14334
MONORAILS WITH MANUAL HOIST
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Monorails With Manual Hoist as shown on the Plans, as specified, and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American Institute of Steel Construction (AISC) Publication:
Steel Construction Manual and 13th Edition
1.2.2 American National Standards Institute, Inc. (ANSI) Publication:
MH27.2 Specifications for Enclosed Track Underhung Cranes and Monorail Systems
1.2.3 American Society of Mechanical Engineers (ASME) Publications:
B30.10 Hooks
B30.11 Monorails and Underhung Cranes
B30.16 Safety Standards for Overhead Hoists (Underhung)
1.2.4 American Society For Testing and Materials (ASTM) Publication:
A275 Magnetic Particle Examination of Steel Forgings
1.2.5 American Welding Society, Inc. (AWS) Publication:
D1.1 Structural Welding Code, Steel
1.2.6 Occupational Safety and Health Administration (OSHA) Publication:
29 CFR Part 1926 Regulations for Construction
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MONORAILS WITH MANUAL HOIST
1.3 VERIFICATION OF DIMENSIONS: The Contractor shall be responsible for the coordination of his work with the work of all trades involved and as it relates to the building structure. The Contractor shall verify all building dimensions that relate to fabrication of the monorail system, and shall notify the Engineer of any discrepancy before order to the monorail manufacturer is finalized.
1.4 SUBMITTALS: Submit the following:
1.4.1 Shop Drawings: Submit Shop Drawings showing the general arrangement of the monorail beam system, including curves and switches, clearances, principal dimensions, details of structural connections, and all component details. In addition, the following related items apply:
a. Manufacturer's standard catalog cuts (Product Data) for all supplied equipment and all accessories.
b. OSHA Compliance Certificate upon completion of field load testing.
1.4.2 Certified Test Reports: Submit certified factory test reports for magnetic particle testing of each hook and hook nut, as well as factory certification of the load chain rated capacity.
1.4.3 Operation and Maintenance Manuals: Submit maintenance manuals (three copies) for the monorail system.
1.5 QUALITY ASSURANCE: Installer shall have a minimum of 3 years experience in, and regularly engaged in, field installation of monorail hoist systems.
PART 2 - PRODUCTS
2.1 FABRICATION AND CONSTRUCTION: The hoist and trolley shall conform to the applicable sections of ASME B30.16, ASME B30.10 and ASME 30.11 and appropriate ASME HST performance standards except as specified otherwise with a Duty Service Classification of “Infrequent Usage (Light Service)” as defined in Table 1 of ANSI MH27.2 (latest edition). Trolley and wheels shall be suitable for operation on the steel monorail track beam provided, and shall have not less than four wheels.
6.19 14334-2 394.107.001 SECTION 14334
MONORAILS WITH MANUAL HOIST
2.1.1 Hoist/Trolley Capacity: The hoist/trolley shall have a minimum rated capacity of 1/2 tons (one ton equals 2,000 pounds). The monorail system shall have a minimum rated capacity of 1 ton.
2.1.2 Hook Lift: The hoist lift shall be at its highest point a minimum of 8 feet above the Pump Station Access Level floor (elevation = 1053.75 feet) and at its lowest point a maximum of 2 feet above the Pump Station Basement Level floor (elevation = 1032.75 feet).
2.1.3 Hooks: Shall be of the safety type with hook nuts keyed to hook shanks by means of a set screw installed in a plane parallel to the longitudinal axis of the hook shank, or by any other similar easily removable securing device. All hook components shall be magnetic particle inspected over the entire area in accordance with ASTM A275. The acceptance standard shall be one of no defects. A defect is defined as a linear indication revealed by magnetic particle inspection that is greater than 1/8 inch long whose length is equal to or is greater than three times its width.
2.1.4 Trolley: Shall be designed to operate from monorail beam section as shown on the Contract Drawings.
2.1.5 Trolley/Hoist: Provide manual hand chain hoist and geared trolley system from single source manufacturer. Trolley/Hoist system shall be 1/2-ton capacity Model CB005-GTF2010 as manufactured by Harrington Hoists and Cranes, or approved equal.
2.2 MONORAIL BEAM SYSTEM: Shall be as shown on the Contract Drawings. The monorail beam system will have trolley stops at all open and end locations. Wheel stops shall interface with the trolley wheel treads on both sides of the track web simultaneously and shall not interface with the trolley wheel flanges.
2.2.1 Color of Finished Equipment: Shall be the manufacturer's standard.
2.2.2 Identification Plates: Provide identification plates of noncorrosive metal. Information and data on the plates shall include, in clearly legible permanent lettering, the manufacturer's name, model number, capacity rating, and other essential information. In addition, the monorail beam system shall have stencil painted four inch high letters/numbers located on the beam so as to be clearly visible from any point on the floor below identifying the monorail/hoist capacity in tons.
6.19 14334-3 394.107.001 SECTION 14334
MONORAILS WITH MANUAL HOIST
PART 3 - EXECUTION
3.1 ERECTION AND INSTALLATION: The Contractor shall erect and install the hoist trolley and monorail beam system in accordance with manufacturer's written instructions, and the Contract Drawings. The monorail trolley/hoist supplier shall provide supervisory erection services.
3.1.1 Do not use monorail crane system for construction.
3.2 FIELD INSPECTION AND TESTS:
3.2.1 Pre-Erection Inspection: Before erection, the Contractor and the manufacturer's representative shall jointly inspect the monorail and hoist systems and components at the job site to determine compliance with Specifications and, manufacturer's data and shop drawings as approved. The Contractor shall notify the Engineer one week (7 days) before the inspection.
3.2.2 Operational Inspection and Tests: Upon completion, and before final acceptance, the hoist, trolley, and monorail shall be given the rated load test specified in ANSI B30.11, carrying 125 percent of the rated capacity, and with the units spaced to obtain maximum possible loads in the monorail track beam systems. Hoists shall hold a static load of 125 percent of the rated load. The systems shall be thoroughly tested in service to determine that each component of the system operates as specified, is properly installed and adjusted, and is free from defects in material, manufacture, installation, and workmanship. The Contractor shall furnish operating personnel, instruments, and all other necessary apparatus at no additional cost to the Owner. The test and final adjustments of the equipment will be under the supervision of the Engineer. The Contractor will furnish loads for testing. The Contractor shall rectify any deficiencies found and completely retest work affected by such deficiencies.
3.2.3 Perform testing in presence of OSHA certifier, manufacturer, Engineer, and Owner.
3.2.4 Operate equipment through complete lift and lowering cycle and through complete travel of trolley to demonstrate quiet, smooth, and safe hoisting, braking, and travel.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - MONORAILS WITH MANUAL HOIST:
4.1.1 Measurement for Monorails With Manual Hoist shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
6.19 14334-4 394.107.001 SECTION 14334
MONORAILS WITH MANUAL HOIST
4.2 PAYMENT - MONORAILS WITH MANUAL HOIST:
4.2.1 For Monorails With Manual Hoist, not included in other unit or lump sum price items, payment for Monorails With Manual Hoist will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 14334-5 394.107.001 SECTION 15011
MECHANICAL GENERAL REQUIREMENTS
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Mechanical General Requirements, as shown on the Plans, as specified and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 Code of Federal Regulations (CFR) Publications:
29-1910-SUBPART O Machinery and Machine Guarding
29-1910.219 Mechanical Power-Transmission Apparatus
1.3 RELATED REQUIREMENTS: This Section applies to certain sections of Division 1, "General Requirements" and Division 2, "Site Work"; and all sections of Division 15, "Mechanical" of this Project Specification, unless specified otherwise in the individual section.
1.4 SUBMITTALS: Submit shop drawings, manufacturer's data, publication compliance, certified test reports, and manufacturer's certificates of compliance for equipment, materials and finish, and pertinent details for each system where specified in each individual section, and have them approved before procurement, fabrication or delivery of the items to the job site. Shop drawings shall be accompanied by a letter of transmittal in duplicate, and all shop drawings shall be suitably identified with the name of the project, contract number, Contractor's name, date and initials indicating approval of such submittal by the Contractor under the applicable specification. Partial submittals will not be acceptable and will be returned without review. Submittals shall include the manufacturer's name, trade name, catalog model or number, nameplate data, size, layout dimensions, capacity, project specification and the specific technical paragraph reference which specifies each item, applicable industry and technical society publication references, and other information necessary to establish contract compliance of each item to be furnished.
1.4.1 Manufacturer's Data: Submittals for each manufactured item shall be current manufacturer's descriptive literature of cataloged products, equipment drawings, diagrams, performance and characteristic curves, and catalog cuts.
4.19 15011-1 394.107.001 SECTION 15011
MECHANICAL GENERAL REQUIREMENTS
1.4.2 Shop Drawings: Drawings shall be a minimum of 8.5 inches by 11 inches in size, except as specified otherwise. Drawings shall include floor plans, sectional views, wiring diagrams, and installation details of equipment; and equipment spaces identifying and indicating proposed location, layout and arrangement of items of equipment, control panels, accessories, piping, ductwork, and other items that must be shown to ensure a coordinated installation. Wiring diagrams shall identify circuit terminals, and indicate the internal wiring for each item of equipment and the interconnection between each item of equipment. Drawings shall indicate adequate clearance for operation, maintenance, and replacement of operating equipment devices.
1.4.3 Manufacturer's Certificates of Compliance: Submit certification from manufacturer attesting that materials and equipment to be furnished for this project comply with the requirements of this specification and of the reference publications. Pre-printed certifications will not be acceptable; certifications shall be the manufacturer's original; certifications shall be not more than one year old. The certification shall not contain statements that could be interpreted to imply that the product does not meet all requirements specified, such as "as good as"; "achieve the same end use and results as materials formulated in accordance with the referenced publications"; "equal or exceed the service and performance of the specified material". The certification shall simply state that the product conforms to the requirements specified. Certificates shall be signed by the manufacturer's official authorized to sign certificates of compliance.
1.4.4 Reference Standards Compliance: Where equipment or materials are specified to conform to industry and technical society reference standards of organizations such as the American National Standards Institute (ANSI), American Society for Testing and Materials (ASTM), National Electrical Manufacturers Association (NEMA), American Society of Mechanical Engineers (ASME), American Gas Association (AGA), American Refrigeration Institute (ARI), and Underwriters' Laboratories (UL), proof of such conformance shall be submitted. If an organization uses a label or listing to indicate compliance with a particular reference standard, the label or listing will be acceptable evidence, unless otherwise specified in the individual sections.
1.4.4.1 Independent Testing Organization Certificate: In lieu of the label or listing, submit a certificate from an independent testing organization, competent to perform testing and approved by the Engineer. The certificate shall state that the item has been tested in accordance with the specified organization's test methods and that the item complies with the specified organization's reference standard.
4.19 15011-2 394.107.001 SECTION 15011
MECHANICAL GENERAL REQUIREMENTS
1.5 OPERATION AND MAINTENANCE MANUAL: Furnish an operation and maintenance manual for each item of equipment. Furnish three copies of the manual bound in hardback binders or an approved equivalent. Furnish one complete manual to the Owner's Representative for review and approval not more than 90 calendar days after an item is approved, but at least 60 calendar days prior to field acceptance testing of the item. Furnish the remaining manuals at least 60 days prior to contract completion. Inscribe the following identification on the cover: the words "OPERATION AND MAINTENANCE MANUAL", the name and location of the equipment or the building, the name of the Contractor, and the contract number. The manual shall include the names, addresses, and telephone numbers of each subcontractor installing equipment, and of the local representatives for each item of equipment. The manual shall have a table of contents and be assembled to conform to the table of contents with the tab sheets placed before instructions covering the subject. The instructions shall be legible and easily read, with large sheets of drawings folded in. The manual shall include: wiring and control diagrams with data to explain detailed operation and control of each item of equipment; a control sequence describing start-up, operation and shut-down; description of the function of each principal item of equipment; the procedure for starting; the procedure for operating; shut-down instructions; installation instructions; maintenance instructions; lubrication schedule including type, grade, temperature range, and frequency; safety precautions, diagrams, and illustrations; test procedures; performance data; and parts list. The parts lists for equipment shall indicate the sources of supply, recommended spare parts, and the service organization which is reasonably convenient to the project site. The manual shall be complete in all respects for equipment, controls, accessories, and associated appurtenances provided.
1.6 CATALOGED PRODUCTS: Materials and equipment shall be cataloged products of manufacturers regularly engaged in production of such materials or equipment and shall be manufacturer's latest design that complies with the specification requirements. Materials and equipment shall duplicate items that have been in satisfactory commercial or industrial use. Where two or more items of the same class of equipment are required, these items shall be products of a single manufacturer; however, the component parts of the items need not be the products of the same manufacturer. Each item of equipment shall have the manufacturer's name, address, model number and serial number on the nameplate securely affixed in a conspicuous place; the nameplate of the distributing agent will not be acceptable.
1.7 LAYOUT OF THE WORK: Coordinate the proper relation of the work to the building structure, existing utilities and to the work of all trades. The Contractor shall advise the Owner's Representative of any discrepancy before performing any work.
4.19 15011-3 394.107.001 SECTION 15011
MECHANICAL GENERAL REQUIREMENTS
1.7.1 Contract Drawings: The Contract Drawings represent the general intent as to piping and equipment arrangements. All locations and dimensions shown shall be field verified and minor alterations made if so required. Where dimensions are not given for the location and arrangement of mechanical systems, locations may be assumed to be approximate, and may be altered if required. Major modifications to the indicated arrangements shall be approved by the Owner's Representative prior to the installation of mechanical systems. Schematic diagrams represent the overall system requirements and do not necessarily indicate the physical orientation, location or dimensions of that system.
1.7.2 Record Drawings: The Contractor shall maintain a record of the progress of the work and shall submit three (3) sets of As-Built Drawings upon completion of the project.
1.8 MANUFACTURER'S RECOMMENDATIONS: Unless otherwise stated in the Contract Specifications, all new equipment items, and specialties shall be installed in strict accordance with the recommendations of the manufacturer of the items being installed. Prior to the installation of new items, the Contractor shall submit to the Owner's representative printed copies of the manufacturer's installation recommendations. Installation of the item will not be allowed to proceed until the recommendations are received. Failure to furnish these recommendations can be cause for rejection of the material. Failure to install items in accordance with manufacturer's recommendations can be cause for rejection of the work items installed.
1.9 DELIVERY, STORAGE, AND HANDLING: Properly store, adequately protect, and carefully handle equipment and materials to prevent damage before and during installation in accordance with the manufacturer's recommendations, and as approved by the Engineer. Replace damaged or defective items.
1.10 SAFETY REQUIREMENTS:
1.10.1 Equipment Safety: Fully enclose or properly guard in accordance with 29 CFR 1910.219 belts, pulleys, chains, gears, couplings, projecting setscrews, keys, rotating parts, and other power transmission apparatus, located where persons can come in close proximity thereto. Points of operation, ingoing nip points, and machinery producing flying chips and sparks shall be guarded in accordance with the applicable portions of 29 CFR 1910-SUBPART O. Provide positive means of locking out equipment so that equipment cannot be accidentally started during maintenance procedures. High-temperature equipment and piping so located as to endanger personnel or create a fire hazard shall be properly guarded or covered with insulation of the type specified. Provide catwalks, maintenance platforms, and guardrails where required for safe operation and maintenance of equipment. Provide ladders or stairways to reach catwalks and
4.19 15011-4 394.107.001 SECTION 15011
MECHANICAL GENERAL REQUIREMENTS
maintenance platforms. Ensure that access openings leading to equipment are large enough to carry through routine maintenance items such as filters and tools.
1.11 ELECTRICAL REQUIREMENTS: Furnish motors, controllers, disconnects and contactors with their respective pieces of equipment. Motors, controllers, disconnects and contactors shall conform to and have electrical connections provided under Division 16. Furnish internal wiring for components of packaged equipment as an integral part of the equipment. Extended voltage range motors will not be permitted. Controllers and contactors shall have a maximum of 120 volt control circuits, and shall have auxiliary contacts for use with the controls furnished. When motors and equipment furnished are larger than sizes indicated, the cost of additional electrical service and related work shall be included under this Section. Power wiring and conduit for field installed equipment shall be provided under and conform to the requirements of Division 16.
1.12 INSTRUCTION TO OWNER'S PERSONNEL: When specified in other sections, furnish the services of competent instructors to give full instruction to the designated Owner's personnel in the adjustment, operation, and maintenance, including pertinent safety requirements, of the specified equipment or system. Instructors shall be thoroughly familiar with all parts of the installation and shall be trained in operating theory as well as practical operation and maintenance work. Instruction shall be given during the first regular work week after the equipment or system has been accepted and turned over to the Owner for regular operation. The number of days (8 hours per day) of instruction furnished shall be as specified in the individual section. When more than 4 days of instruction are specified, use approximately half of the time for classroom instruction. Use other time for instruction with the equipment or system. When significant changes or modifications in the equipment or system are made under the terms of the Contract, provide additional instruction to acquaint the operating personnel with the changes or modifications.
1.13 INSPECTIONS AND CERTIFICATIONS: The Contractor shall provide and pay for any third party inspections or certifications required by applicable regulatory agencies for boilers and other mechanical equipment components modified, or furnished and installed as a part of the Contract work.
PART 2 - PRODUCTS
Not Used.
4.19 15011-5 394.107.001 SECTION 15011
MECHANICAL GENERAL REQUIREMENTS
PART 3 - EXECUTION
3.1 FIELD PAINTING: Conform to Section 09900, "Painting."
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - MECHANICAL GENERAL REQUIREMENTS:
4.1.1 Measurement for Mechanical General Requirements shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - MECHANICAL GENERAL REQUIREMENTS:
4.2.1 For Mechanical General Requirements, not included in other unit or lump sum price items, payment for Mechanical General Requirements will be made at the applicable price stated in the Bid.
END OF SECTION
4.19 15011-6 394.107.001 SECTION 15075
PIPING SYSTEMS
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Piping Systems, as shown on the Plans, as specified and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American National Standards Institute (ANSI) Publications:
B1 Unified Inch Screw Threads (UN and UNR Thread Form)
B2.1 Pipe Threads (Except Dryseal)
B2.4 Hose Coupling Screw Threads
B16.5 Pipe Flanges and Flanged Fittings
B16.10 Face-to-Face and End-to-End Dimensions of Ferrous Valves
B16.21 Nonmetallic Flat Gaskets for Pipe Flanges
B16.34 Valves-Flanged and Buttwelding End
B18.2.1 Square And Hex Bolts and Screws Inch Series Including Hex Cap Screws and Lag Screws
B18.2.2 Square and Hex Nuts
B31.9 Building Services Piping
B40.1 Gauges-Pressure Indicating Dial Type-Elastic Element
Z49.1 Safety In Welding and Cutting
6.19 15075-1 394.107.001 SECTION 15075
PIPING SYSTEMS
1.2.2 American Society for Testing and Materials (ASTM) Publications:
A194 Carbon and Alloy Steel Nuts for Bolts for High-Pressure and High-Temperature Service
A276 Stainless and Heat-Resisting Steel Bars and Shapes
A307 Carbon Steel Externally Threaded Standard Fasteners
A386 Zinc-Coating (Hot-Dip) on Assembled Steel Products
A525 Sheet Steel, Zinc-Coated (Galvanized) by the Hot-Dip Process
A774 As-Welded Wrought Austenitic Stainless Steel Fittings for General Corrosive Service at Low and Moderate Temperatures
D1654 Painted or Coated Specimens Subjected to Corrosive Environments
1.2.3 Manufacturers Standardization Society of the Valve and Fittings Industry (MSS) Publications:
SP 58 Pipe Hangers and Supports - Materials, Design and Manufacture
SP 69 Pipe Hangers and Supports - Selection and Application
1.3 SUBMITTALS:
1.3.1 Manufacturer's Data:
a. Piping and Fittings b. Gaskets c. Valves d. Piping Accessories e. Hangers and Supports
6.19 15075-2 394.107.001 SECTION 15075
PIPING SYSTEMS
1.4 SAFETY PRECAUTIONS:
1.4.1 Rotating Equipment Safety: Fully guard couplings, motor shafts, gears and other exposed rotating or rapidly moving parts in accordance with ASME B15.1. The guards shall be cast iron or expanded metal. Guard parts shall be rigid, secured, and readily removable without disassembling the guarded unit.
1.4.2 Welding and Cutting Safety: ANSI Z49.1.
PART 2 - PRODUCTS
2.1 PIPING SCHEDULE: Piping shall be provided in accordance with the following schedule unless specified or indicated otherwise.
SERVICE SIZES PIPE JOINT Landfill Collection Mains Primary Leachate 8" Perforated Secondary Leachate 8” SDR-11 HDPE Butt-Fusion Groundwater 8" Leachate Conveyance From Sideriser Buildings to Leachate Cell No. 6”/10” SDR 17 HDPE Butt-Fusion 12/13 Leachate Collection Manhole Flanged or Leachate Tie-In Manhole Interior Piping All Schedule 80 PVC Cemented (As Shown) Flanged or Cell No. 12/13 Leachate Collection All Schedule 80 PVC Cemented (As Manhole Interior Piping Shown) Flanged or Cemented Sideriser Building Piping All Schedule 80 PVC (As Shown) Sideriser Pipes 24” SDR 17 HDPE Butt-Fusion Sideriser Force Main 2” SDR 11 HDPE Butt-Fusion
Leachate Conveyance Pipe From
Leachate Cell No. 12/13 Leachate
Collection Manhole to Pump Station Dual Contained No. 3 (MPS-3) Butt-Fusion 12”/16” SDR-17 HDPE
6.19 15075-3 394.107.001 SECTION 15075
PIPING SYSTEMS
Flanged or Pump Station PS-3 Piping All Schedule 80 PVC Cemented (As Shown) Leachate Conveyance from PS-3 to Dual Contained 10”/14” Butt-Fusion Force Main Cleanout Manhole SDR 17 HDPE Flanged or Force Main Maintenance/Cleanout All Schedule 80 PVC Cemented (As Manholes (3) Shown) Perforated and Leachate Storage Tank Secondary 4” Solid SDR 17 Cemented Containment Leak Detection Piping HDPE SDR 17 HDPE Butt-Fusion Leachate Storage Tank No. 3 Fill and All Drain Piping (at tank) Schedule 40 Welded or flanged Stainless Steel Fill Piping from Leachate Loadout 10”/14” Dual Contained Butt-Fusion Building to Leachate Storage Tank SDR 17 HDPE No. 3 10” SDR 17 HDPE Butt-Fusion
Drain Piping from Leachate Storage 8”/10” Dual Contained Butt-Fusion Tank No. 3 to Leachate Loadout SDR 17 HDPE Building 8” SDR 17 HDPE Butt-Fusion
2” Schedule 40 Threaded Galvanized Steel, ASTM A120
Bubbler Air Piping Copper Soldered
Schedule 80 PVC Flanged or Cemented (as shown) See Sections 15492 “Fuel Gas Piping” and 15495 Fuel System Piping “Fuel Piping” Domestic Water and DWV Piping See Section 15400 “Plumbing”
6.19 15075-4 394.107.001 SECTION 15075
PIPING SYSTEMS
2.2 PIPING, FITTINGS AND ACCESSORIES:
2.2.1 PVC Piping: PVC piping and fittings shall be as specified in Section 02436, "Polyvinyl Chloride (PVC) Pipe and Fittings".
2.2.2 HDPE Piping: HDPE piping and fittings shall be as specified in Section 02674, "High Density Polyethylene (HDPE) Pipe and Fittings".
2.2.3 Stainless Steel Piping:
2.2.3.1 Piping and Fittings: Piping shall be ASTM A778 or ASTM A312, Type 304L stainless steel, Schedule 40, welded or flanged as shown, with Class 150, ASTM A774, Type 304L stainless steel fittings.
2.2.4 Flanged Joints:
2.2.4.1 Flanges: Provide ANSI B16.1, Class 150 flanges for all flange connections. Backup rings shall be lightweight stainless steel.
2.2.4.2 Bolting of Flanges: Material used for bolts and studs shall be stainless steel conforming to ASTM A276, Type 304, and material for nuts shall be stainless steel conforming to ASTM A276, Type 304. Dimensions of bolts, studs, and nuts shall conform to ANSI B18.2.1 and ANSI B18.2.2 with threads conforming to ANSI B1.1 coarse type with Class 2A fit for bolts and studs, and Class 2B fit for nuts. Bolts or studs shall extend through the nuts and may have reduced shanks of a diameter not less than the diameter at root of threads. Stainless steel bolts shall have American Standard regular square or heavy hexagon heads and shall have American Standard heavy, semi-finished hexagonal nuts.
2.2.4.3 Gaskets: All flange gaskets shall be Viton, suitable for the pressure and temperature ranges encountered, and compatible with the flange faces. Dimensions for nonmetallic gaskets shall conform to ANSI B16.21.
2.2.5 Valves:
2.2.5.1 Pinch Valves: Provide pinch valves of cast iron, closed construction, Class 150 flanged connections, and full-port Viton sleeve with sleeve spring construction to return sleeve to full-port configuration when opened from closed position. Valves shall be as manufactured by Red Valve (Series 5200), or equal.
6.19 15075-5 394.107.001 SECTION 15075
PIPING SYSTEMS
2.2.5.2 Knife Gate Valves: Provide valves constructed of cast iron body, stainless steel knife, wafer type construction with tapped and threaded Class 150 bolt holes and replaceable Viton sleeve. Valve shall be capable of 150 psig maximum working pressure. Provide knife gate valves with lockable valve stands and extension riser stems where indicated. Knife gate valves shall be as manufactured by Red Valve (Flex Gate), or equal.
2.2.5.3 Ball Valves 2-1/2 Inches and Larger: Valves shall be 275 WOG rated, Type 316 stainless steel body, ball and stem, two position handle operation, replaceable reinforced Teflon seats, full port and Class 150 flange connections. Manufacture shall be as by Apollo 87-200 Series, or equal.
2.2.5.4 Ball Valves (Leachate): Valves shall be PVC Type 1, Grade 1, cell classification conforming to ASTM D1784, suitable for use with landfill leachate. Ball valves shall be Safe Block True Union full port valves with Viton O-ring seals as manufactured by Hayward, or equal. Valves shall have self-lubricating TFE seats.
2.2.5.5 Ball Valves (Gas/Air): 600 psi cwp, cast brass bodies, two-position hand levers, replaceable reinforced Teflon seats, conventional port, blow-out proof stems, chrome-plated brass ball threaded ends with extended solder cups. Manufacture shall be as by Stockham, Crane, Apollo, or equal.
2.2.5.6 Check Valves 2-1/2 Inches and Larger: Valves shall be swing type, Class 125, flanged, ASTM A126, Class B iron body and disc, with bolted cap and stainless steel trim. Valve shall be as manufactured by Stockham, Figure 933, or equal.
2.2.5.7 Air Vacuum Valve: The valve body, cover, and baffle shall be constructed of ASTM A126 Class B cast iron for working pressures up to 150 psig. The orifice, float and linkage shall be constructed of Type 316 stainless steel. All seals shall be Viton and the valve shall be fully automatic. Float operated valve shall be manufactured by Val-Matic (VM-1003), or equal. Provide isolation ball valve to all air/vacuum release components.
2.2.5.8 Ball Valves 3 Inches and Smaller: Valves shall be PVC Type 1, Grade 1, cell classification conforming to ASTM D1784, suitable for use with landfill leachate. Ball valves shall be Safe Block True Union full port valves with Viton O-ring seals as manufactured by Hayward, or equal. Valves shall have self-lubricating TFE seats.
2.2.5.9 Check Valves 4 Inches and Smaller: Check valves shall be ball type, operate in either the horizontal or vertical position, and shall have a full flow design to reduce pressure drop. The valve shall have a true union design constructed of PVC, and shall be suitable for use with landfill leachate. Check valves shall be "True Check" ball check valves as manufactured by
6.19 15075-6 394.107.001 SECTION 15075
PIPING SYSTEMS
2.2.6 Piping Sleeves: Provide sleeves for all pipe penetrations through floors, walls or ceilings. Standard sleeves shall be Schedule 40 steel. Provide cast-in-place ductile iron, cement- lined wall pipe type sleeves with integral water stop flange at the locations shown and with the end connections indicated on the Contract Drawings. Manufacture shall be as by Clow, or equal.
2.2.7 Compressible Seals: Provide seals which completely seal the space between pipe and sleeve by a system of interlocking synthetic rubber links shaped to continuously fill the space when tightened. Seals shall be as manufactured by Thunderline Corporation (Link-Seal), or equal.
2.2.8 Expansion Joints: Expansion joints shall consist of an inner tube, body, and outer cover constructed of Viton, and shall have flanged ends. The body shall be reinforced with steel wire for strength. Flanges shall be constructed integrally with the body to resist stresses and shall be full-pattern so gaskets are not necessary. Flanges shall be drilled ANSI B16.5, Class 150#. The expansion joints shall be open single arch construction allowing for a minimum of 1-3/4” axial compression, 3/4” axial elongation and 1” lateral deflection with a working pressure of 140 psi. Provide 304 SS retaining rings. All expansion joints shall be Redflex Type J1W Wide Arch as manufactured by Red Valve Co, Inc, or approved equal. Provide reducing expansion joints where noted.
PART 3 - EXECUTION
3.1 INSTALLATION: Install piping and piping components to ensure proper and efficient operation of the equipment and controls and in accordance with manufacturer's printed instructions. Provide proper supports for the mounting of vibration isolators, stands, guides, anchors, clamps and brackets. Arrange piping connections to equipment so that the removal of equipment or components of equipment including pump casings, shaft seals and similar work can be accomplished with the least amount of disassembly or removal of the piping system. Electric isolation shall be provided between dissimilar metals to reduce the rate of galvanic corrosion. All pipe and fittings shall be carefully handled by means of suitable equipment, in such a manner as to prevent damage to materials and protective coatings or linings. Under no circumstances shall materials be dropped or damaged during installation. Pipe or fittings which are damaged during construction shall be repaired or replaced at no expense to the Owner.
3.2 PIPING SYSTEMS: Cut to the measurements established at the site and work into place without springing or forcing. Install piping with line flexibility included to absorb the expansion and contraction due to temperature changes of the piping systems. Piping line flexibility shall be achieved by the use of pipe bends or loops.
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PIPING SYSTEMS
3.2.1 Flanged Joints: Faced true, square, tight and used as indicated and where necessary for normal maintenance. Mate with valves and the various equipment connections. Remove the raised faces from fittings or equipment having raised faces. Flanged joints shall be firmly bolted with through, stud or tap bolts. All bolts and nuts shall have washers. All bolts, nuts, and washers shall be 304 stainless steel.
3.2.2 Reducing Fittings: Use to connect changes of sizes in piping lines. Make branch connections with tees except that factory-made saddles having integral gasketing and clamps be used if the nominal diameter of the piping system branch does not exceed two nominal pipe sizes less than the nominal size of the main piping.
3.2.3 Insulation: Piping insulation shall be in accordance with Section 15250, "Insulation of Mechanical Systems", with enough clearance allowed between pipes to permit application of the insulation.
3.2.4 Dielectric Unions or Flanges: Provide between ferrous and nonferrous piping, equipment, and fittings; except that bronze valves and fittings may be used without dielectric couplings for ferrous-to-ferrous or nonferrous-to-nonferrous connections. Flanges and unions shall conform to the requirements of ANSI B16.10.
3.2.5 Pipe Hangers and Supports: Design and fabrication of pipe hangers, supports, and welding attachments shall conform to MSS SP 58. Hanger types and supports for bare and covered pipes shall conform to MSS SP 69 for the system temperature range. Unless otherwise indicated, horizontal and vertical piping attachments shall conform to MSS SP 58. Where required, structural members, pipe columns and concrete, where shown or indicated, shall also be used as means of pipe support. Provide metal protection shields and inserts for insulated piping in accordance with Section 15250, "Insulation of Mechanical Systems".
3.3 LEACHATE PIPING:
3.3.1 Fabrication and Assembly of Piping and Components: Assembly and connection of plastic piping (PVC or HDPE) shall be in accordance with the appropriate specification section and as specified herein. Provide sufficient pitch to assure adequate drainage and venting. Provide drain valves at low points of piping system, and air vent valves at high points where air pockets would occur. All piping shall follow the general arrangement shown, cut accurately to measurements established for the work by the Contractor, and worked into place without springing or forcing. All piping and equipment within structures shall be entirely out of the way of electrical conduit, lighting fixtures, equipment and doors, and other openings. Provide adequate clearance from walls, ceilings, and floors to permit the connection of joints and to permit work between the pipe and wall. Provide for expansion and contraction of pipelines.
6.19 15075-8 394.107.001 SECTION 15075
PIPING SYSTEMS
Make changes in size of pipelines with reducing fittings. Do not bury, conceal, or insulate piping until inspected, tested, and approved. Protect materials and equipment from the weather. Run all pipe to be insulated as shown and as required with sufficient clearance to permit application of insulation. Do not miter pipe to form elbows, or notch straight runs to form full-sized tees, or utilize any similar construction. Except where shown otherwise, run vertical piping plumb and straight and parallel to walls. Thoroughly clean each section of pipe, fittings, and valves to be free of all foreign matter before erection. Prior to erection, hold each piece of pipe in an inclined position and thoroughly tap to loosen sand, mill scale, and foreign matter. Before all final connections are made to apparatus, wash the interior of all piping thoroughly with water. Blow out piping with compressed air or flush with water to remove rust scale, oil, and debris. Plug or cap open ends of mains during all shutdown periods. Do not leave lines open at any place where foreign matter might accidentally enter.
3.3.1.1 Cutting of pipe shall be done with pipe cutters, motor drive saws using abrasive disks, or with handsaws as required. Where machining is necessary for cut ends or for extending factory machining, it shall be done in accordance with the manufacturer's recommendations for the type of pipe and joint used. The flame cutting of pipe by means of an oxyacetylene torch will not be allowed.
3.3.1.2 Fittings and pipe within structures shall be placed to line and grade and properly supported before joints are made. The Contractor shall furnish all the necessary pipe supports, including stirrups, rods, clamps, hangers, pipe columns and piers, necessary to sustain the pipe and fittings in a firm and substantial manner to the lines and grades given.
3.3.1.3 Valves: Install at all equipment items to allow maintenance or isolation, and to establish proper and sequential operation of the complete system.
3.4 CLEANING OF SYSTEMS: When installations of the various components of the piping systems are completed, clean by flushing with water before final closing. Clean all piping and components of scale and thoroughly flush out all foreign matter. Clean all strainers and valves thoroughly. Wipe equipment clean, removing all traces of oil, dust, dirt, or paint spots. Maintain the system in this clean condition until final approval. Clean and paint piping and equipment as specified herein.
3.5 FIELD TESTS: After completion of the piping installation and prior to initial operation, conduct tests on the piping system. Furnish materials and equipment required for tests. Correct defects disclosed by the test. Perform test after installation and prior to acceptance in the presence of the Owner's Representative and subject to his approval.
6.19 15075-9 394.107.001 SECTION 15075
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3.5.1 Primary Containment Leachate Piping: Hydrostatically test in accordance with the requirements of ANSI B31.9 and the manufacturer's recommendations. Test piping system at one and one-half times system pressure but at least 50 psig with water not exceeding 100 degrees F. Before tests, remove or isolate gauges and other apparatus in the new system which may be damaged by the high pressure. Repair leaks. Do not caulk joints. Install a calibrated, test pressure gauge in the system to observe loss in pressure. Maintain the required test pressure for a sufficient amount of time to enable an inspection of joints and connections. Correct defects disclosed by the test.
3.5.2 Secondary Containment Leachate Piping: Pneumatically test all secondary containment piping in accordance with the manufacturer's recommendations. Piping incorporating compressible seal type containment terminations shall be tested at a minimum pressure of 2 psig for a period of not less than one hour.
3.6 INSPECTION: All pipelines shall be visually inspected by means of pipeline television camera and recorded permanently on video cassette or DVD. Provide three (3) copies of the record video. Any deficiencies, contamination or abnormalities determined by the camera inspection of the pipelines shall be repaired and re-inspected by television camera after the repair. All necessary repairs and re-inspections shall be provided at no additional cost to the Owner.
3.7 STARTUP AND OPERATIONAL TESTS: Start up and initially operate the system. During this time, observe the operation of the system and correct any defects or abnormalities which may occur in the overall system.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - PIPING SYSTEMS:
4.1.1 Measurement for Piping Systems shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - PIPING SYSTEMS:
4.2.1 For Piping Systems, not included in other unit or lump sum price items, payment for Piping Systems will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 15075-10 394.107.001 SECTION 15122
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PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for the complete installation and operation of Leachate System Mechanical Equipment items as shown on the Plans, as specified and/or directed.
1.1.2 Contract No. 1A shall furnish all Leachate System control systems labor, materials and equipment for a complete installation and operation as specified herein. It is the intention of this Specification that all equipment specified or required under this Section shall be provided by one supplier who will function as the System Integrator and provide one contact for future service. System integration shall be the responsibility of Contract No. 1A. All power and control wiring between interrelated components shall be by Contract No. 1B. Contract No. 1B shall terminate all power and control field wiring under the direct supervision and witnessed by Contract No. 1A.
1.1.3 Contract No. 1A shall coordinate with Contract No. 1B for all wiring size and type for all equipment connections specified herein.
1.1.4 Leachate System Mechanical Equipment shall include:
a. Primary Sideriser Pumping System (PSP-12, PSP-13) b. Secondary Sideriser Pumping System (SSP-12, SSP-13) c. Sideriser Building Sump Floats (two) d. Pump Station Pumps (P-1, P-2, P-3) e. Pump Station Level Control System f. Pump Station Sump Pump (PSSP-1)
1.1.5 Control Panels:
a. Sideriser Pumping System Control Panel (SR-CP-12, SR-CP-13) b. Pump Station Pump Control Panel (PCP) c. Pump Station Sump Pump Control Panel (PSSP-CP)
1.1.6 The work also includes all accessories, control stations, appurtenances or other work required for a complete operating installation of the specified equipment, except those items specifically included under other items of this Contract.
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1.2 GENERAL REQUIREMENTS: Section 15011, "Mechanical - General Requirements", with the additions and modifications specified herein, applies to this Specification.
1.3 SUBMITTALS:
1.3.1 Manufacturer's Data: Submit Shop Drawings and schematics for the following:
a. Primary Sideriser Pumping System (PSP) b. Secondary Sideriser Pumping System (SSP) c. Sideriser Flow Meters d. Sideriser Flow Meters Flow Transmitters and Flow Totalizer/Computers e. Sideriser Liquid Level Sensors f. Sideriser Pumping System Control Panel (SR-CP-12, SR-CP-13) g. Pump Station Pumps (P-1, P-2, P-3) h. Pump Station Level Control System i. Pump Station Pump Control Panel (PCP) j. Pump Station Sump Pump (PSSP-1) k. Pump Station Sump Pump Control Panel (PSSP-CP) l. Pump Station Electromagnetic Flow Meters
1.3.2 Standards of Compliance and Manuals: Submit standards compliance information as well as operation and maintenance manuals for the equipment furnished.
1.4 LEACHATE CONTROLS SEQUENCING:
1.4.1 Leachate Sideriser Buildings (Sideriser Building No. 12 and No. 13):
1.4.1.1 When the liquid level in the pump station containment area or wet well reaches the “Alarm Level (Containment Area)” or “HIGH –HIGH LEVEL (Wet Well)” floats the side riser control panels systems shall initiate the shutdown of the primary and secondary pumps within that both sideriser buildings. The system shall initiate an alarm condition to the existing SCADA system and require resets of the pump systems. Resets shall be required to be manually at the local panels for each Sideriser Building.
1.4.2 Primary Sideriser Pumps
1.4.2.1 When the primary sideriser pumps are off and the liquid level within the primary sump reaches the “Lead Pump On” transducer level, operation of the lead pump shall be initiated. The pump shall continue to run until the liquid level reaches the “All Off” and the lead pump is turned off.
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1.4.2.2 If the liquid level within the primary sump continues to rise during the operation of the Lead Pump, the Lag Pump shall be initiated once the level reaches the “Lag Pump On” transducer level. The pump shall continue to run until the liquid level reaches the “All Off” level and both pumps are turned off.
1.4.2.3 If the liquid levels continue to rise with both the Lead and Lag pumps operating, a High Alarm shall be initiated once the liquid level reaches the “High Alarm” transducer level. The pumps shall continue operation under a “High Alarm” condition unless shut down for other reasons.
1.4.2.4 If at any time a pump is running and no flow indicated for a period of 60 seconds (programmable adjustable time limit), the pump(s) shall shut off and a “pump failure due to no flow” alarm shall initiate.
1.4.2.5 The sideriser control panels will also alternate the lead/lag pump following each pumping sequence to allow for approximately equal run times for both primary pumps.
1.4.2.6 Each pump controller shall include a Hand Auto switch. In auto position, pumps shall start based on the sump transducer level or remote start command. Hand position (spring return to auto) shall start pump and pump until “All Off” level triggers pumps off.
1.4.3 Secondary Sideriser Pump:
1.4.3.1 When the primary sideriser pumps are off and the liquid level within the primary sump reaches the “Pump On” transducer level, operation of the lead pump shall be initiated. The pump shall continue to run until the liquid level reaches the “Off” and the pump is turned off.
1.4.3.2 If the liquid levels continue to rise with both the pump operating, a High Alarm shall be initiated once the liquid level reaches the “High Alarm” transducer level. The pumps shall continue operation under a “High Alarm” condition unless shut down for other reasons.
1.4.3.3 If at any time a pump is running and no flow indicated for a period of 60 seconds (programmable adjustable time limit), the pump shall shut off and a “pump failure due to no flow” alarm shall initiate.
1.4.3.4 Each pump controller shall include a Hand Auto switch. In auto position, pumps shall start based on float or remote start command. Hand position (spring return to auto) shall start pump and pump until “All Off” level triggers pumps off.
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1.4.4 Leachate Pump Station Sump Pump:
1.4.4.1 When the liquid level in the floor sump reaches the “PUMP ON” float, the PSSP-CP system shall turn on the pump station sump pump (PSSP-1). When the liquid level in the floor sump reaches the “PUMP OFF” float, the PSSP-CP system shall turn off the pump station sump pump (PSSP-1).
1.4.4.2 When the liquid level in the floor sump reaches the “Alarm” float, the PSSP-CP system shall initiate shutdown of the pump station pumps (P-1, P-2, P-3) and all primary and secondary sideriser pumps (PSP-12, PSP-13, SSP-12, SSP-13). The PSSP-CP system shall initiate an alarm condition to the existing SCADA system and require manual reset of the pump systems.
1.4.5 Leachate Pump Station Secondary Containment:
1.4.5.1 When the liquid level in the secondary containment reaches the “Alarm” float, the PCP system shall initiate shutdown of all primary and secondary sideriser pumps (PSP-12, PSP- 13, SSP-12, SSP-13). The PCP system shall initiate an alarm condition to the existing SCADA system and require manual reset of the pump systems.
1.4.6 Leachate Pump Station Pumps:
1.4.6.1 When the Pump Station pumps are off and the liquid level within the Wet Well reaches the “Lead Pump On” float level, operation of the lead pump (P-1) shall be initiated. The pump shall continue to run until the liquid level reaches the “All Off” and the small pump is turned off.
1.4.6.2 If the liquid level within the Wet Well continues to rise due to higher flows during the operation of the P-1, the Lag Pump (P-2 or P-3) shall be initiated once the level reaches the “Lag Pump On” float level. The pump shall continue to run until the liquid level reaches the “All Off” level and both pumps are turned off.
1.4.6.3 If the liquid levels continue to rise with both the Lead and Lag pumps operating, a High Alarm shall be initiated once the liquid level reaches the “High Alarm” float level. The pumps shall continue operation under a “High Alarm” condition unless shut down for other reasons.
1.4.6.4 The pump station control panel will also alternate the lead/lag pump following each pumping sequence of Pumps P2 and P3 to allow for approximately equal run times for both primary pumps.
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1.5 SUBMITTALS:
1.5.1 Submittals Required: Supply shop drawing submittal information on the following equipment:
a. Systems schematics, including ladder diagrams, wiring diagrams, set points, operating ranges, voltages, currents, mounting locations and terminal strip points, and interconnection diagrams.
b. Sequence of operation for each system and function.
c. Generic, functional description of each control component shown on the drawings.
d. Control panels.
e. Equipment interlocks required by sequence of operation.
f. Mounting details.
g. Complete program documentation for all control equipment.
h. The name, address and telephone number of a local (150 miles or less) factory authorized service organization with a statement of the maximum time required to have a service technician after telephone notification of an equipment malfunction. Existing sideriser pumps at the site are serviced by Pump Service and Supply, Troy New York 518-272-0388.
i. The name, address and telephone number of a local (150 miles or less) factory authorized parts distributor with a statement of the maximum time (must be 24 hours or less) required to deliver standard replacement parts for the equipment supplied. Existing sideriser pumps at the site are serviced by Pump Service and Supply, Troy New York 518-272-0388.
1.6 QUALITY ASSURANCE: Contractor shall provide complete operating control and instrumentation systems. The Contractor shall supply the services of manufacturer’s factory trained start-up technician to assure all equipment has been satisfactorily installed, is properly calibrated and operates to the satisfaction of the Owner.
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1.6.1 Operation and Maintenance Manuals: After final acceptance of the system, furnish six (6) copies of an operation and maintenance manual for each indicated item of equipment. The manual shall have a Table of Contents and be assembled to conform to the Table of Contents with the tab sheets placed before instructions covering the subject. The instructions shall be legible and easily read, with large sheets of drawings folded in. the manual shall include: wiring and control diagrams and interconnection diagrams with data to explain detailed operation and control of each item of equipment; a control sequence describing start-up, operation and shutdown; description of the function of each principal item of equipment; the procedure for starting; the procedure for operating; shutdown instructions; installation instructions; maintenance instructions; safety precautions, diagrams, and illustrations; test procedures; performance data; and parts list.
1.6.2 Software and Licensing: provide copies of software in a Windows format which will allow the Owner to program or modify program for any and all components. Provide CD ROM and hard copies of all initial programming in a format acceptable for the Owner.
PART 2 - PRODUCTS
2.1 PRIMARY SIDERISER PUMPING SYSTEM (PSP): Provide complete and operational "turn-key" package pumping system incorporating sideriser pump, pump carriage, discharge hose, retrieval cable, control system, accessories and specialties necessary for pumping of landfill leachate via a sideriser collection system as shown and indicated on the Contract Drawings.
2.1.1 Pump: The pumps shall be explosion-proof, submersible type, suitable for the pumping of landfill leachate in a Class I, Division I classified space in the sloped or horizontal position.
2.1.2 The pump system shall be designed to operate under the following conditions with the characteristics noted:
Cell No. 12 and 13 (4 pumps total) Capacity, gpm 65 Total Head, ft. 35’ Discharge, inches 2” Motor horsepower 1.5
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2.1.3 Motor shall be housed in a cast iron air filled watertight casing.
2.1.3.1 Motor shall be capacitor start, capacitor run type designed for 460 volt, 3 phase, 60 hertz service. Motor shall have Class F insulation capable of resisting a maximum operating temperature of 155o C under full load in a submerged condition. Motor shall have bearings, designed for a B-10 life of 30,000 hours. A heat sensor thermostat shall be attached to the top end of motor winding and shall be connected to series with the magnetic contactor coil in control box to stop motor if winding temperature reaches 140o C. Thermostat shall automatically reset when motor cools. The starter chamber shall include a float leakage sensor for the detection of water in the motor chamber, the leakage sensor shall stop operation of the pump if liquid is detected within the motor and energize a red alarm light mounted in the control panel.
2.1.3.2 The motor shall be protected by two mechanical seals mounted in tandem with an oil filled chamber between the seals for lubrication. Seal faces shall be carbon and ceramic lapped to a flatness tolerance of one light band. Metal parts and spring shall be stainless steel. A sending electrode shall be mounted in the chamber to detect any water leakage past the lower seal. Upon water leakage past the seal, the electrode shall activate a red signal light located on the control panel but shall not cause the pump to become inoperable.
2.1.3.3 Motor power cable shall be type SO (7 conductor, or number as required by manufacturer, cable) of sufficient length to reach from the bottom of the sideriser sump to termination strip in control panel. The power cable shall be hypalon coated, or equal. Provide enough slack to allow for pump removal. Cable shall be potted into motor end cap with epoxy potting compound. In addition, a rubber grommet that seals cable shall be clamped onto cable by end holding cap.
2.1.3.4 Ends of cable shall be suitably protected by a watertight seal until final installation.
2.1.4 The pump impeller shall be cast iron with cast iron rotary cutter and hardened 316 stainless steel stationary cutter, suitable for the cutting and grinding the pumped liquid into a fine slurry.
2.1.5 All iron castings shall be treated with phosphate and chromic rinse and painted with a high temperature baked-on epoxy coating before machining and all exposed machined surfaces recoated. All fasteners shall be 302 stainless steel. The exterior and hydraulic interior of the pump shall be coated with a 2-part epoxy coating resistant to the typical leachate constituents, such as Belzona (1341), or equal.
2.1.6 Pump Carriage: The pump shall be mounted in a stainless steel carriage designed for use in a 24" HDPE riser pipe set at an approximate 3:1 slope. The carriage shall provide a low center of gravity and all wheels shall remain in contact with the contour of the riser pipe. The
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wheels shall be of non-corrosive materials with self-lubricating qualities, and the unit must be able to travel over welding beads as typically found in riser pipe fabrications. All fasteners shall be stainless steel. The pump and motor shall be easily removed from the carriage in the field should the pump require service.
2.1.6.1 A 0.25" safety/retrieval cable assembly with properly sized cable clips, snap hook of 300 Series stainless steel shall be provided, connected to the pump carriage for removal and installation of the pump into the sideriser pipe.
2.1.7 Discharge Pipe Assembly: Pump discharge shall be 2-inch diameter.
2.1.7.1 Side Exit Fittings: A side exit assembly shall be provided at the top of the sideriser pipe and connected to the discharge pipe with a flanged connection. Assembly shall include full port PVC ball valve, PVC ball check valve and pressure gauge as shown. All bolts and fittings shall be 300 series stainless steel.
2.1.8 Liquid Level Sensors: Provide submersible type pressure transducer level sensors for adjustable pump level control and alarm. Sensors shall be constructed of 300 series stainless steel with 4-20mA output signal, suitable for long term operation in landfill leachate and attached to the pump carriage assembly at the appropriate elevations. Cable/tube lengths shall be adequate to reach control panel in one continuous length. Provide each sensor with a permanently sealed bellows type breather unit mounted in the control panel to prevent moisture from entering and forming in the transducer.
2.1.8.1 Each sensor shall be suitable for use in an intrinsically safe control system.
2.1.9 Special Tools and Spare Parts: The pump manufacturer shall furnish the following:
a. One set of special tools required for the maintenance of the pump. b. One complete set of shaft seals. c. One set of wearing rings for each pump. d. One set of cutters (stationary and rotary). e. Two spare intrinsically safe couplers. f. Two spare fuses of each kind and size used. g. Four spare bulbs for each kind and size of pilot light.
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2.2 SECONDARY SIDERISER PUMPING SYSTEM (SSP): : Provide complete and operational "turn-key" package pumping system incorporating sideriser pump, pump carriage, discharge hose, retrieval cable, control system, accessories and specialties necessary for pumping of landfill leachate via a sideriser collection system as shown and indicated on the Contract Drawings.
2.2.1 Pump: The pumps shall be explosion-proof, submersible type, suitable for the pumping of landfill leachate in a Class I, Division I classified space in the sloped or horizontal position.
2.2.2 The pump system shall be designed to operate under the following conditions with the characteristics noted:
Cells No. 12 and 13 (2 total) Capacity, gpm 65 Total Head, ft. 35’ Discharge, inches 2” Motor horsepower 1.5
2.2.3 Motor shall be housed in a cast iron air filled watertight casing.
2.2.3.1 Motor shall be capacitor start, capacitor run type designed for 460 volt, 3 phase, 60 hertz service. Motor shall have Class F insulation capable of resisting a maximum operating temperature of 155o C under full load in a submerged condition. Motor shall have bearings, designed for a B-10 life of 30,000 hours. A heat sensor thermostat shall be attached to the top end of motor winding and shall be connected to series with the magnetic contactor coil in control box to stop motor if winding temperature reaches 140o C. Thermostat shall automatically reset when motor cools. The starter chamber shall include a float leakage sensor for the detection of water in the motor chamber, the leakage sensor shall stop operation of the pump if liquid is detected within the motor and energize a red alarm light mounted in the control panel.
2.2.3.2 The motor shall be protected by two mechanical seals mounted in tandem with an oil filled chamber between the seals for lubrication. Seal faces shall be carbon and ceramic lapped to a flatness tolerance of one light band. Metal parts and spring shall be stainless steel. A sending electrode shall be mounted in the chamber to detect any water leakage past the lower seal. Upon water leakage past the seal, the electrode shall activate a red signal light located on the control panel but shall not cause the pump to become inoperable.
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2.2.3.3 Motor power cable shall be type SO (7 conductor, or number as required by manufacturer, cable) of sufficient length to reach from the bottom of the sideriser sump to termination strip in control panel. Provide enough slack to allow for pump removal. Cable shall be potted into motor end cap with epoxy potting compound. In addition, a rubber grommet that seals cable shall be clamped onto cable by end holding cap.
2.2.3.4 Ends of cable shall be suitably protected by a watertight seal until final installation.
2.2.4 The pump impeller shall be cast iron with cast iron rotary cutter and hardened 316 stainless steel stationary cutter, suitable for the cutting and grinding the pumped liquid into a fine slurry.
2.2.5 All iron castings shall be treated with phosphate and chromic rinse and painted with a high temperature baked-on epoxy coating before machining and all exposed machined surfaces recoated. All fasteners shall be 302 stainless steel.
2.2.6 Pump Carriage: The pump shall be mounted in a stainless steel carriage designed for use in a 24" HDPE riser pipe set at an approximate 3:1 slope. The carriage shall provide a low center of gravity and all wheels shall remain in contact with the contour of the riser pipe. The wheels shall be of non-corrosive materials with self-lubricating qualities, and the unit must be able to travel over welding beads as typically found in riser pipe fabrications. All fasteners shall be stainless steel. The pump and motor shall be easily removed from the carriage in the field should the pump require service.
2.2.6.1 A 0.25" safety/retrieval cable assembly with properly sized cable clips, snap hook of 300 Series stainless steel shall be provided, connected to the pump carriage for removal and installation of the pump into the sideriser pipe.
2.2.7 Discharge Pipe Assembly: Pump discharge shall be 2-inch diameter.
2.2.7.1 Side Exit Fittings: A side exit assembly shall be provided at the top of the sideriser pipe and connected to the discharge pipe with a flanged connection. Assembly shall include full port PVC ball valve, PVC ball check valve and pressure gauge as shown. All bolts and fittings shall be 300 series stainless steel.
2.2.8 Liquid Level Sensors: Provide submersible type pressure transducer level sensors for adjustable pump level control and alarm. Sensors shall be constructed of 300 series stainless steel with 4-20mA output signal, suitable for long term operation in landfill leachate and attached to the pump carriage assembly at the appropriate elevations. Cable/tube lengths shall be adequate to reach control panel in one continuous length. Provide each sensor with a
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permanently sealed bellows type breather unit mounted in the control panel to prevent moisture from entering and forming in the transducer.
2.2.8.1 Each sensor shall be suitable for use in an intrinsically safe control system.
2.2.9 Special Tools and Spare Parts: The pump manufacturer shall furnish the following:
a. One set of special tools required for the maintenance of the pump. b. One complete set of shaft seals. c. One set of wearing rings for each pump. d. One set of cutters (stationary and rotary). e. Two spare intrinsically safe couplers. f. Two spare fuses of each kind and size used. g. Four spare bulbs for each kind and size of pilot light.
2.3 SIDERISER CONTROL PANEL (SR-CP-12, SR-CP-13):
2.3.1 Sideriser Pumping System Control Panels (SR-CP-12, CR_CP-13): Panels shall be UL 508A listed and manufactured by a UL 508A approved panel shop. The control panel shall be constructed in accordance with the UL 698A provisions. Pump systems shall include automatic pump control panel in a NEMA 4 enclosure constructed of 14 gauge 304 stainless steel shall be furnished and installed. The panels shall have a tamperproof cover, shall be furnished with padlock hasp and full inner sub-door and shall be designed for connection to 480 volt, 3 phase, 4 wire, 60 hertz service. Panels shall be wall mounted and installed on the exterior of the Sideriser Buildings as shown on the Contract Drawings.
2.3.1.1 The panels shall also include the following:
a. A main circuit breaker, 480 volt, 3 phase service. (Operable handle on panel exterior.) b. Test switches to manually monitor level sensors operation. c. Individual 3 phase motor circuit breaker disconnect for each pump starter. d. Individual across the line motor starter with integral ambient compensated solid state adjustable overload for each pump motor and through the door reset buttons. e. An alarm circuit consisting of an alarm relay, flasher, horn and an alarm silence button. The alarm relay is activated by the various alarms as specified herein. The alarm silence button to deactivate the horn only. The flasher/alarm light will remain in service until the alarm is corrected. f. Thermal/moisture sensor IS relays for all pumps. g. Integral 480-120/240V control power transformer. Transformer kVA per
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manufacturer’s requirements for control panel power including PLC, flow computers, loop power supplies, IS power supplies, panel heater, alarm, etc. Provide primary and secondary fuse protection. h. PLC or equivalent for pump/alarm operation as required per this Specification. PLC or controller must be able to communicate alarm and control status to the existing site SCADA System. i. Individual pump elapsed time meter (ETM). j. Intrinsically safe type relay for connection to the sideriser building sump level sensor. k. Heavy-duty LED style pilot lights. l. MOV type distribution lightning arrestor (Category B & C) and TVSS protection for all field wired control/signal circuits, motor branch circuits and incoming power feeder circuit. m. Thermostatically controlled panel heater. n. 3 port 4-20mA intrinsically safe (IS) barrier relays and power supplies as necessary to provide individually isolated 4-20mA signals for three (3) level sensors and three (3) flow sensors, and alarm inputs to PLC for each system. Integrate 4-20mA signal from flow sensors with flow computers (primary and secondary). o. All externally mounted devices shall be NEMA 4 rated. p. Viewing windows on panel exterior for viewing flow computers (computers mounted on interior panel). q. Hand-Off-Auto (HOA) switches for each pump (primary and secondary) r. Phase monitor protection system s. Fiber patch panel for a minimum of four (4) fibers
2.3.1.2 All internal panel wiring shall be run in neat bundles secured by wire ties or nonmetallic slotted raceways. All wires shall have wire numbers at each termination.
2.3.1.3 All items shall be wired to numbered terminal strips for connection to external wiring.
2.3.1.4 Intrinsically safe relays and alarm actuation wiring shall be protected by grounded barriers from any power wiring. Such wiring shall also not be run parallel to any power wiring.
2.3.1.5 The SR-CP-12 and SR-CP-13 PLC shall transmit/activate the following alarms/status points and/or as specified herein:
a. Primary Pump #1 overload - Alarm b. Primary Pump #2 overload - Alarm c. Secondary Pump overload - Alarm d. Primary Pump #1 Run - Status
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e. Primary Pump #2 Run - Status f. Secondary Pump Run - Status g. PLC fault – Alarm h. Phase Monitor Fault – Alarm and shut down pumps (primary and secondary) i. Sump High Level – Alarm and shut down pumps (primary and secondary) j. Pump Station High Level Alarm – Remote alarm from new pump station autodialer. Shut down pumps (primary and secondary). k. Pump Failure Due To No Flow – Alarm and shut down pump (typical for Primary Pump #1, Primary Pump #2 and Secondary Pump: only shutdown particular pump that was called to run). l. High Level Primary #1 Side Riser – Alarm m. High Level Primary #2 Side Riser – Alarm n. High Level Secondary Side Riser – Alarm o. Primary Pump #1 flow – status (4-20mA input from flow computer) p. Primary Pump #2 flow – status (4-20mA input from flow computer) q. Secondary flow – status (4-20mA input from flow computer)
2.3.1.6 The SR-CP shall have the following alarm LED lights and control switches mounted on the exterior of the panel:
a. Primary Pump #1 Run b. Primary Pump #2 Run c. Secondary Pump Run d. Primary Pump #1 Overload e. Primary Pump #2 Overload f. Secondary Pump Overload g. Primary Pump #1 Fail to Pump h. Primary Pump #2 Fail to Pump i. Secondary Pump Fail to Pump j. Sump High Level Alarm k. Sideriser High Level Alarm l. SR-CP System Alarm (power monitor, PLC failure, etc.) m. Pump HOAs n. Pump ETM’s
2.3.1.7 Flow Meters: Provide insertion style paddle wheel type flow meter with non- metallic construction of wetted parts. Flow meter shall incorporate a non-magnetic sensing mechanism and six-bladed paddle wheel with a design flow range of 0.5 to 30 ft/sec and 1.0% accuracy. Meter shall incorporate 4-20 mA or 12-40 VDC scaled pulsed output for connection to a remote flow computer display unit compatible with the flow meter and to 3 port
6.19 15122-13 307.107.001 SECTION 15122
LEACHATE SYSTEM MECHANICAL EQUIPMENT
isolation/barrier relay. Meter shall be suitable for use in a Class 1, Division 2 hazardous space. Meter shall be as manufactured by GF Signet (515 Rotor-X Paddlewheel), or equal.
2.3.1.8 Flow Computers: Provide each flow meter with remote flow computer compatible with the flow meter with LCD display/keypad interface, nonvolatile memory and visual display of instantaneous volumetric flow rate (GPM) and totalized flow (gallons). Provide form C type dry contact (programmable) to initiate “flow meter error” at SR-CP. Mount all flow computers on interior panel. Main panel exterior to have exterior viewing window(s) to allow viewing of flow computers without having to open panel door. Flow computer shall be as manufactured by GF Signet (9900 Transmitter), or equal.
2.4 PHASE MONITOR: A phase monitor shall be supplied to protect three-phase equipment against phase loss, undervoltage and phase reversal conditions. When a fault is sensed, the monitor output relay opens within two seconds or less to turn all pumps off and initiate an alarm at the SR-CP. Both Delta and Wye systems may be monitored. The monitor shall have an automatic reset and shall also include an adjustable voltage delay. The monitor shall have an indicator LED (glows when the conditions are normal and shall monitor phase sequence: ABD operate (will not operate CBA)). The phase monitor shall be UL approved and CSA certified.
2.5 SURGE ARRESTOR: A secondary arrestor shall be provided. Housing shall be Noryl and be ultrasonically sealed. Valve blocks shall be metal oxide with an insulating ceramic collar. Gap design shall be annular. The lead wire shall be permanently crimped to the upper electrode forming part of the gap structure. Arrestors shall be UL and CSA listed Lightning Protective Devices.
2.6 SPARE PUMP: Provide one additional spare pump complete with power cable of the same length as provided for the other pumps. Spare pump shall be as specified herein for the based bid and additive bid if awarded.
2.7 PUMP STATION PUMPS (P-1, P-2, P-3):
2.7.1 Pumps: Pumps shall be heavy-duty, vertical, dry-pit, non-clog, single stage centrifugal end suction type, suitable for variable speed pumping of landfill leachate.
2.7.2 Pumps shall be designed to operate under the following conditions with the characteristics noted:
6.19 15122-14 307.107.001 SECTION 15122
LEACHATE SYSTEM MECHANICAL EQUIPMENT
Pump Nos. P-1 Capacity at Max. Speed (gpm) 160 Total Head (ft.) 16.5 Minimum Shutoff Head (ft.) 24 Minimum Net Pump Suction Head (ft.) 9 Pump Suction, Inches 4 Pump Discharge, Inches 3 Maximum RPM 1,165 Maximum Motor HP 2 Minimum Efficiency at Operating Point 69%
Pump Nos. P-2 and P-3 Capacity at Max. Speed (gpm) 880 Total Head (ft.) 68 Minimum Shutoff Head (ft.) 112 Minimum Net Pump Suction Head (ft.) 19.7 Pump Suction, Inches 6 Pump Discharge, Inches 4 Maximum RPM 1,765 Minimum Motor HP 25 Minimum Efficiency at Operating Point 76%
2.7.2.1 Pumps shall be as manufactured by Fairbanks Morse to match the existing pump station, or approved equal.
2.7.3 The pumps shall rotate in the direction shown, and shall fit into the space provided on the plans, without undue adjustment of the piping. When operating over the specified range of conditions, the pumps shall not cavitate and shall be free of undue noise and vibration.
2.7.4 Pump Construction:
2.7.4.1 Pump casings shall be close-grained cast iron of sufficient strength, weight and metal thickness to insure long life, accurate alignment, and reliable operation. Volute shall have smooth fluid passages large enough at all points to pass small size solids through the impeller and provide smooth unobstructed flow. Suction and discharge connections shall be ANSI B16.1, Class 125 standard flat-faced flanges. Casings shall be provided with a baked on epoxy coating on all interior wetted parts.
6.19 15122-15 307.107.001 SECTION 15122
LEACHATE SYSTEM MECHANICAL EQUIPMENT
2.7.4.2 A replaceable AISI 410 stainless steel suction cover wear plate, providing 1/4" minimum wear, shall be installed with its wear surface parallel to the end of the impeller.
2.7.4.3 The pump impellers shall be of the two-vane cast iron enclosed non-clog type. Impellers shall be statically, dynamically and hydraulically balanced and keyed and secured to the shaft by a bronze nut locked in place and shall be readily removable without the use of special tools. Impellers shall be coated with a baked on epoxy coating. Pump shall have provision for adjustment of impeller axial clearance. Adjustment shall be made through the use of shims placed between the frame and outboard bearing housing. A replaceable AISI 410 stainless steel "L" shaped wear ring shall be provided on the impeller. Ring shall be mounted on the impeller to provide a renewable surface opposite the suction cover wear plate.
2.7.4.4 Pump shafts shall be high grade alloy steel, accurately machined over the entire length and shall be protected by a renewable stainless steel shaft sleeve.
2.7.4.5 Pump shall incorporate grease lubricated, double mechanical seals of Tungsten Carbide and silicon carbonate. Seals shall be lubricated by means of plunger type grease lubricator. Lubricator shall be pressurized by means of a pilot line to the high pressure zone of the pump volute to maintain grease pressure to the pump seal housing during pump operation. Lubricator shall be as manufactured by Zimmer & Francescon, or equal.
2.7.4.6 Each pump and motor shall be supported by a heavy-duty base assembly constructed of fabricated steel and bolted to the periphery of the pump casing. The base assembly shall incorporate a cast iron cleanout type suction elbow with removable hand hole cover and Class 125 flat face flanges. The entire base assembly shall be designed to safely withstand all stresses imposed thereon by vibrations, shock and all possible direct and eccentric loads.
2.7.4.7 Pump bearings shall be designed for 30,000 hours minimum life per AFBMA test procedure at design head and capacity characteristics. Bearings shall be ball or roller type suitable for all loads encountered in the service conditions. Bearings shall be grease lubricated with provisions for the addition and relief of grease.
2.7.4.8 The pump shall be provided with a motor support of sufficient size and strength to support the driving motor required by the pump. The motor mounting surface shall be designed for standard NEMA "P" flange motor, directly mounted to the pump casing assembly. The entire weight of the motor shall be borne directly by the pump casing and support assembly and in no case shall be transmitted through any portion of the pump itself.
6.19 15122-16 307.107.001 SECTION 15122
LEACHATE SYSTEM MECHANICAL EQUIPMENT
2.7.5 Motors: Pump motors shall be premium efficiency, vertical, TEFC type, 2 horsepower (P-1), 25 horsepower (P-2, P-3), 3 phase, 60 hertz, 480 volt, direct drive with 1,765 rpm running speed suitable for inverter duty use with an IGBT Type variable frequency drive.
2.7.6 Testing:
2.7.6.1 The pumps shall be factory tested by the pump manufacturer in accordance with the standards of the Hydraulic Institute. The Engineer shall be notified in writing at least two weeks prior to factory testing and shall be allowed to witness testing. Five certified copies of the test data shall be furnished to the Engineer.
2.7.6.2 In addition to factory testing, as a condition of acceptance by the Owner the pumps shall be field tested to confirm that they are meeting the minimum specified performance characteristics.
2.7.6.3 Each pump shall be factory tested to provide certification that head, capacity and input power requirements are met. Test data shall be utilized to prepare specific curves; curves shall include the pump serial number and certification by a registered Professional Engineer.
2.8 PUMP STATION LEVEL CONTROL SYSTEM:
2.8.1 The Level Control System shall consist of an Owner provided programmable logic controller (PLC) based system control and data acquisition (SCADA) system within a pump station control panel, a level sensor mounted within the wet well, a liquid level transmitter mounted adjacent to the control panel, variable frequency drives, and associated appurtenances. With the exception of the PLC control panel, all pump station level control system equipment shall be provided by Contract No. 1A. With the exception of the wet well level sensing equipment, all of the pump station level control system equipment shall be installed as a part of the work for Contract No. 1B. The installation of the pump station level control system equipment will be done under the direct supervision of the Owner’s control system consultant. Final programming and configuration of the pump station level control system shall also be accomplished by the Owner’s control system consultant.
2.8.2 Variable Frequency Drives (VFDs): Furnish each pump drive motor with a variable frequency drive, matched to the pump motors for the variable speed operation of the pumps. Drives shall be for use with 480 volt, 3 phase, 1,750 rpm inverter duty rated pump motors, minimum speed of 900 rpm.
6.19 15122-17 307.107.001 SECTION 15122
LEACHATE SYSTEM MECHANICAL EQUIPMENT
2.8.3 Drives shall have the following functions:
a. variable and constant torque applications b. minimum power factor of .95; minimum 97% efficient at full load c. maximum allowable voltage fluctuation of ±10% d. Sine wave PWM output e. field adjustable, maximum 15,000 hz carrier frequency f. insulated gate bipolar transistors (IGBT's) g. 100% rated torque at 1.5 hz and 150% rated torque at 3 hz h. local display and digital keypad (remote mount on MPS-CP face) i. hand-off-auto (H-O-A) selector switch with auxiliary contacts for each position for SCADA connection and position indication. j. 4-20 mA and 0-10 VDC speed control input k. fault indications for under voltage, over voltage, over temperature, instantaneous over current, ground fault, overload threshold exceeded, overload shutdown, processor fault l. drive to be capable of running without load connected m. start/stop by remote contact closure/opening n. any drive fault to actuate a common output contact for actuating a drive fault pilot light and auxiliary contact for SCADA connection and indication of “drive fault” condition. o. drive shall have input line reactor and shall have data submitted to prove unit shall not exceed harmonic distortion limitations of IEEE S19-1992 Table 10.2, without line reactor p. drive shall be adjusted to limit minimum pump motor speed to no less than 30% of full speed q. drive shall provide electronic overload protection for the pump motor r. provide output line reactor matched to VFD and motor electrical characteristics s. drive shall be able to operate a motor “on the fly” t. capability for regenerative braking u. have capability for auto restart after power outage
2.8.3.1 Drive manufacture shall be Allen Bradley, Square-D, or equal.
2.8.4 Wet Well Level Sensing Equipment:
2.8.4.1 Equipment: Level sensing unit for the pump station wet well level shall be Drexelbrook Universal II level sensing system (Model 508-45), or equal. The unit shall be suitable for operation in a Class 1, Group D, Division 1 area. The level sensing unit shall include:
6.19 15122-18 307.107.001 SECTION 15122
LEACHATE SYSTEM MECHANICAL EQUIPMENT
a. Two wire cote shield type electronic level sensing element with explosion proof and corrosive resistant housing and intrinsically safe. The unit shall be for remote flange mounting instilling well within the pump station wet well.
b. Two wire sensing element constructed of stainless steel with PFA insulation.
c. All cable between remote transmitter unit and sensing element.
d. All required fittings, condulets, mounting hardware, weights, etc.
e. Remote transmitter with local readout in feet to nearest 0.1 feet.
f. Accuracy shall be ±1% or greater.
g. Installation, and operation and maintenance manual.
h. Intrinsically safe barrier relay for level transmitter.
i. 4-20 mA output to the PLC and 11.5 - 50 VDC power input from the PLC
j. Length to match the wet well depth and stilling well mounting flange (nominal 13.0 feet).
2.9 PUMP STATION SUMP PUMP (PSSP-1):
2.9.1 Pump: Provide cast iron submersible pump, oil-filled, ball bearing design with mechanical carbon and ceramic seals and cast iron semi-open type impeller. Pump motor shall be 120 volt, 1 phase, 60 hertz. Pump shall be designed for the following operation:
Capacity 56 gpm Total Head 28 ft. Minimum Shutoff Head 47 ft. RPM 3,450 Minimum HP 1/2 hp
2.9.1.1 Pump shall be as manufactured by ABS Pumps, Model SESI-5; Hydromatic Pumps, Model SP 50, or equal.
6.19 15122-19 307.107.001 SECTION 15122
LEACHATE SYSTEM MECHANICAL EQUIPMENT
2.9.2 Sump Pump Controls:
2.9.2.1 Control Panel (PSSP-CP): Provide sump pump control panel with type NEMA 12 enclosure constructed of 14 gauge cold rolled steel and finished in baked enamel with tamperproof cover, padlock hasp, for connection to 120 volt, 1 phase, 3 wire, 60 hertz service at the location shown on the Contract Drawings.
2.9.2.1.1 Panel shall include main circuit breaker disconnect with door mounted operating handle, an across-the-line 300 volt rated motor starter with ambient compensated overloads and applicably sized heaters, a hand-off-automatic selector, reset button and elapsed time meter and run pilot light. Panel shall have loss of phase protection. Controls shall be 120 volt rated. Panel shall have relays for connection to remote float controls with a "high dry well" flashing pilot light energized by the "high level" float switch. Panel shall include auxiliary high level alarm contacts for connection to SCADA system. Relays shall be protected by grounded barriers from any power wiring. All wiring internal to panel shall be run in neat bundles secured by wire ties or run in nonmetallic slotted raceways. All internal wiring shall have wire numbers at each termination. Panel shall include numbered terminal strips for connection of field wiring to remote devices.
2.9.2.2 Provide three (3) displacement type liquid level sensors as specified herein and installed as shown.
2.10 LIQUID LEVEL SENSORS:
2.10.1 Each sensor shall consist of a mercury type float switch in a smooth, non-fiberglass, chemical resistant casing, internally weighted, and suspended on its own cable. Cable length shall be adequate to reach control panel in one continuous length.
2.10.2 Sensors shall be field-mounted and wired to control panel.
2.10.3 Each sensor shall be suitable for use in an intrinsically safe control system.
2.11 CLOSED PIPE ELECTROMAGNETIC FLOW METER: Provide electromagnetic flow meter suitable for the full pipe flow measurement of landfill leachate in PVC pipe. Meter shall be compatible with the pipe sizes indicated and shall incorporate 4-20 mA or 12-40 VDC scaled pulsed output for connection to a remote flow computer display unit compatible with the flow meter. Meter shall be suitable for use in a Class 1, Division 2 hazardous space. Meter shall be as manufactured by Endress+Hauser (Promag P – 50P2H) or equal.
6.19 15122-20 307.107.001 SECTION 15122
LEACHATE SYSTEM MECHANICAL EQUIPMENT
2.11.1 Flow Computer/Display Unit: Provide remote mounted flow computer/display unit with field adjustable and field programmable multi-function capability, 120V AC power input, integral keyboard, graphic display of flow rate and/or totalized flow in standard and metric units, digital/analog output and RS-232 communication port. Unit shall utilize phase detection technology and be capable of both transit-time and Doppler mode operation.
PART 3 - EXECUTION
3.1 INSTALLATION: Install mechanical equipment as indicated and in accordance with the manufacturers' instructions. Provide clearance for inspection, repair, replacement and service. Electrical work shall conform with NFPA 70 and DIVISION 16, "Electrical". Include overload protection in the operating disconnect switches and magnetic starters where provided.
3.1.1 Provide uni-strut channel as necessary to install SR-CP-12 and SR-CP-13 to sideriser building exterior wall. For SR-CP-12 and SR-CP-13, provide additional blocking and through bolt connections as necessary to support weight of control panel. Provide uni-strut channel for all panels within pump station control room as noted on drawings. All exterior enclosures shall be installed with a minimum of 1” air space behind enclosure.
3.2 INITIAL OPERATION AND FIELD TESTS:
3.2.1 Initial Operation: The Contractor shall provide for an authorized manufacturer's representative to initially start and operate each equipment item to show that it is properly installed and will perform satisfactorily. In addition to the time assigned for equipment start-up, sufficient working days shall be allotted to enable the qualified representative to thoroughly instruct the Owner's operating personnel in the operation and maintenance of the equipment.
3.3 FIELD TESTS: Schedule and administer operational performance tests for each item of mechanical equipment as applicable. Operational tests shall be of the duration necessary to compile the test information required, but not less than 2 hours for each pump. Provide for a minimum of 8 hours of start-up service by an authorized factory service personnel for each equipment system.
3.3.1 A start-up report shall be issued by the manufacturer's representative at the initial start- up and operational testing of the equipment items. As a minimum, the recorded information shall list the following items:
a. Meg ohm readings of power and control conductors. b. Amperage reading of each leg of motor leads. c. Rated voltage and measured voltage.
6.19 15122-21 307.107.001 SECTION 15122
LEACHATE SYSTEM MECHANICAL EQUIPMENT
d. Elapsed time readings on each pump at the time of each test. e. Actual equipment output performance quantities derived from field readings of equipment systems measurements.
3.3.2 Oil and grease as required for initial operation will be furnished and shall be in accordance with the manufacturer's recommendation.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - LEACHATE SYSTEM MECHANICAL EQUIPMENT:
4.1.1 Measurement for Leachate System Mechanical Equipment shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - LEACHATE SYSTEM MECHANICAL EQUIPMENT:
4.2.1 For Leachate System Mechanical Equipment, not included in other unit or lump sum price items, payment for Leachate System Mechanical Equipment will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 15122-22 307.107.001 SECTION 15190
MECHANICAL IDENTIFICATION
PART 1 – GENERAL
1.1 DESCRIPTION: Under this Section, the Contractor shall furnish all labor, materials and equipment for identification of mechanical equipment including all pumps, fans, air handling units, VAV boxes, piping and valves using color bands, lettering, flow direction arrows, and related permanent identification devices for Mechanical Identification, as shown on the Plans, as specified and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American National Standards Institute, Inc. (ANSI) Publications:
A13.1 Scheme for the Identification of Piping Systems
Z535.1 Safety Color Code
1.3 GENERAL REQUIREMENTS: The following related sections shall be referenced for further information: Section 15011, “ Mechanical General Requirements”, Section 15400, “Plumbing”, Section 15492, “Fuel Gas Piping”, Section 15850, “Air Handling and Distribution Equipment” and Section 15895, “Ductwork and Ductwork Accessories”.
1.4 SUBMITTALS: The following shall be submitted in accordance with Section 15011, “Mechanical General Requirements”:
a. Label, Tag and Nameplate materials b. List of wording, symbols, letter size, and color coding to be used c. Valve chart d. Accessory materials
PART 2 - PRODUCTS
2.1 MANUFACTURERS: Pipe labels, valve tags and equipment nameplates shall be as manufactured by Marking Services Incorporated, or equal.
4.19 15190-1 394.107.001 SECTION 15190
MECHANICAL IDENTIFICATION
2.1.1 NAMEPLATES: Three-ply laminated phenolic plastic at least 1/16” thick with black surfaces and white core. Engraving shall be minimum ½” high with appropriate spacing. Text shall be white on black background. Nomenclature shall match the equipment designation as indicated on the Plans and Schedules.
2.1.2 VALVE TAGS: Three-ply laminated phenolic plastic at least 1/16” thick with black surfaces and white core. Engraving shall be minimum ½” high with appropriate spacing. Text shall be white on black background. Valve tag shall be minimum 1-1/2” diameter with smooth edges.
2.1.3 PIPE MARKERS: Color, text and size shall conform to ASME/ANSI Standard A13.1.
a. Plastic Pipe Markers: Strap-type labels shall be factory fabricated, flexible, semi- rigid plastic, preformed to fit around pipe or pipe covering with flow direction arrows and identification of fluid being conveyed. Straps shall be self locking nylon ties.
b. Plastic Tape Pipe Markers: Self adhesive flexible, vinyl film tape with pressure sensitive adhesive backing and printed markings with flow direction arrows and identification of fluid being conveyed.
2.1.4 VALVE CHART: Valve chart(s) shall be printed on 8-1/2”x11” white paper with typewritten black text, minimum 12 point character size. Information to be provided shall be, at a minimum, the number, location, size and function of each line valve installed under this Contract. Chart shall be installed in a glazed frame and permanently mounted to wall in mechanical room or other suitable location coordinated with the NYS OPRHP.
PART 3 - EXECUTION
3.1 PREPARATION: Degrease and clean surfaces to receive adhesive for identification materials. Prepare surfaces in accordance with Section 09900, “Painting”.
3.2 GENERAL: All markers shall be installed in accordance with manufacturer’s printed instructions, and shall be neat and uniform in appearance. All tags or markers shall be oriented such that they are readily visible from all normal working locations. All equipment above lift- out ceilings or made accessible by access doors shall be labeled in the same manner as that of exposed equipment.
4.19 15190-2 394.107.001 SECTION 15190
MECHANICAL IDENTIFICATION
3.3 NAMEPLATES: Install plastic nameplates with corrosive-resistant mechanical fasteners, or adhesive. Apply with sufficient adhesive to ensure permanent adhesion and seal with clear lacquer. Equipment to be labeled shall include but not be limited to the following items: pumps, exhaust fans, air handling units, hot water heaters, boilers, HVAC control devices and dampers, switches, control panels and other related devices.
3.4 VALVE TAGS: Install valve tags on all valves except simple service and drain valves located within 10 feet and sight distance of the device or equipment served. For example, it would not be expected that valves at a pressure reducing station in a machine room would be tagged. Each tag shall be attached to its valve with copper clad annealed iron wire, corrosion resistant chain, or other approved material.
3.5 PIPE MARKERS: Exposed piping shall be identified at intervals of 20 feet and at least one time in each room. Provide a pipe marker at each valve. Provide arrow markers at each pipe marker with arrows pointing away from the pipe marker to indicate direction of flow. When flow can be in either or both directions, provide a double ended arrow marker. Provide pipe and arrow marker at every point of pipe entry or exit where line penetrates a wall or service column. Self-adhesive labels shall be used to identify piping under 6 inches in diameter when insulated and covered. For finished pipe sizes 6 inches and larger, strap type markers with self-locking nylon ties shall be utilized.
3.6 MISCELLANEOUS EQUIPMENT: Small items such as inline pumps shall be identified with tags in lieu of nameplates. Submit labeling plan to Engineer for devices and equipment not otherwise specified herein.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - MECHANICAL IDENTIFICATION:
4.1.1 Measurement for Mechanical Identification shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT – MECHANICAL IDENTIFICATION:
4.2.1 For Mechanical Identification, not included in other unit or lump sum price items, payment for Mechanical Identification will be made at the applicable price stated in the Bid.
END OF SECTION
4.19 15190-3 394.107.001 SECTION 15400
PLUMBING
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Plumbing, as shown on the Plans, as specified and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American National Standards Institute (ANSI) Publications:
A112.6.1M Supports for Off-the-Floor Plumbing Fixtures for Public Use
A112.18.1M Finished and Rough Brass Plumbing Fixture Fittings
A112.19.1M Enameled Cast Iron Plumbing Fixtures
A112.19.2M Vitreous China Plumbing Fixtures
A112.19.3 Stainless Steel Plumbing Fixtures (Designed for Residential Use)
A112.19.4M Porcelain Enameled Formed Steel Plumbing Fixtures
A112.19.5 Trim for Water-Closet Bowls, Tanks, and Urinals
A112.21.1M Floor Drains
A112.21.2M Roof Drains
A112.26.1M Water Hammer Arresters
A112.36.2M Cleanouts
B16.1 Cast-Iron Pipe Flanges and Flanged Fittings, Class 25, 125, 250 and 800
6.19 15400-1 394.107.001 SECTION 15400
PLUMBING
B16.3 Malleable-Iron Threaded Fittings
B16.12 Cast-Iron Threaded Drainage Fittings
B16.18 Cast Copper Alloy Solder Joint Pressure Fittings
B16.22 Wrought Copper and Copper Alloy Solder Joint Pressure Fittings
B16.23 Cast Copper Alloy Solder Joint Drainage Fittings -DWV
B16.24 Bronze Pipe Flanges and Flanged Fittings, Class 150 and 300
B16.26 Cast Copper Alloy Fittings for Flared Copper Tubes
B16.29 Wrought Copper and Wrought Copper Alloy Solder Joint Drainage Fittings - DWV
B16.32 Cast Copper Alloy Solder Joint Fittings for Solvent Drainage Systems
B16.39 Malleable-Iron Threaded Pipe Unions, Class 150, 250 and 300
B40.1 Gauges, Pressure Indicating Dial Type, Elastic Element
Z21.22 Relief Valves For Hot Water Supply Systems
Z124.1 Plastic Bathtub Units
Z124.2 Gel-Coated Glass-Fiber Reinforced Polyester Resin Shower Receptors and Shower Stall Units
Z358.1 Emergency Eye Wash and Shower Equipment
6.19 15400-2 394.107.001 SECTION 15400
PLUMBING
1.2.3 American Society for Testing and Materials (ASTM) Publications:
A47 Ferritic Malleable-Iron Castings
A53 Pipe, Steel, Black and Hot-Dipped, Zinc-Coated Welded and Seamless
A74 Cast-Iron Soil Pipe and Fittings
A120 Pipe, Steel, Black and Hot-Dipped, Zinc-Coated (Galvanized) Welded and Seamless for Ordinary Uses
A183 Carbon Steel Track Bolts and Nuts
A536 Ductile-Iron Castings
B32 Solder Metal
B61 Steam or Valve Bronze Castings
B62 Composition Bronze or Ounce Metal Castings
B88 Seamless Copper Water Tube
B306 Copper Drainage Tube (DWV)
C564 Rubber Gaskets for Cast-Iron Soil Pipe and Fittings
D2000 Classification System for Rubber Products in Automotive Applications
D2661 Acrylonitrile-Butadiene-Styrene (ABS) Plastic Drain, Waste, and Vent Pipe and Fittings
D2564 Solvent Cements for Poly(Vinyl Chloride) (PVC) Plastic Pipe and Fittings
D2665 Poly(Vinyl Chloride) (PVC) Plastic Drain, Waste and Vent Pipe and Fittings
6.19 15400-3 394.107.001 SECTION 15400
PLUMBING
D2846 Chlorinated Poly(Vinyl Chloride) (CPVC) Plastic Hot-and Cold-Water Distribution Systems
F439 Socket-Type Chlorinated Poly(Vinyl Chloride) (CPVC) Plastic Pipe Fittings, Schedule 80
F441 Chlorinated Poly(Vinyl Chloride) (CPVC) Plastic Pipe, Schedules 40 and 80
F493 Solvent Cements for Chlorinated Poly(Vinyl Chloride) (CPVC) Plastic Pipe and Fittings
1.2.4 American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) Publication:
90A Energy Conservation in New Building Design
1.2.5 American Society of Sanitary Engineering (ASSE) Publications:
1003 Water Pressure Reducing Valves for Domestic Water Supply Systems
1010 Water Hammer Arresters
1019 Wall Hydrants, Frost Proof Automatic Draining, Anti-backflow Types
1.2.6 American Water Works Association (AWWA) Publications:
C104 Cement-Mortar Lining for Ductile-Iron and Gray-Iron Pipe and Fitting for Water
C105 Polyethylene Encasement for Ductile-Iron Piping for Water and Other Liquids
C110 Gray-Iron and Ductile-Iron Fittings, 3 in. Through 48 in. for Water and Other Liquids
6.19 15400-4 394.107.001 SECTION 15400
PLUMBING
C111 Rubber-Gasket Joints for Ductile-Iron and Gray-Iron Pressure Pipe and Fittings
C115 Flanged Ductile-Iron and Gray-Iron Pipe with Threaded Flanges
C151 Ductile-Iron Pipe, Centrifugally Cast in Metal Molds or Sand-Lined Molds, for Water and Other Liquids
C500 Gate Valves, 3 Through 48 inch NPS, for Water and Sewage Systems
C504 Rubber Seated Butterfly Valves
C651 Disinfecting Water Mains
C700 Cold-Water Meters, Displacement Type
C701 Cold-Water Meters, Turbine Type for Customer Service
C702 Cold-Water Meters, Compound Type
1.2.7 Cast Iron Soil Pipe Institute (CISPI) Publications:
301 Hubless Cast-Iron Soil Pipe and Fittings for Sanitary and Storm Drain, Waste, and Vent Piping Applications
310 Patented Joint for Use in Connection with Hubless Cast-Iron Sanitary System
HSN Neoprene Rubber Gaskets for Hub and Spigot Cast Iron Soil Pipe and Fittings
1.2.8 Manufacturers Standardization Society of the Valve and Fittings Industry (MSS) Publications:
SP 58 Pipe Hangers and Supports - Materials, Design and Manufacture
6.19 15400-5 394.107.001 SECTION 15400
PLUMBING
SP 67 Butterfly Valves
SP 69 Pipe Hangers and Supports - Selection and Application
SP 70 Cast Iron Gate Valves, Flanged and Threaded Ends
SP 80 Bronze Gate, Globe, Angle and Check Valves
SP 85 Cast Iron Globe and Angle Valves, Flanged and Threaded Ends
1.2.9 National Fire Protection Association (NFPA) Publications:
54 National Fuel Gas Code
58 Liquified Petroleum Gas Code
211 Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances
1.2.10 Plumbing and Drainage Institute (PDI) Publication:
WH201 Water Hammer Arresters
1.2.11 Uniform Fire Prevention and Building Code of New York State Publications:
2015 International Plumbing Code
2017 Uniform Code Supplement
1.2.12 Foundation for Cross-Connection Control and Hydraulic Research, University of Southern California (FCCCHR) Publication:
List of Approved Backflow Prevention Assemblies (Obtain current date from NAVFAC HQ, Code 04)
1.3 GENERAL REQUIREMENTS: Section 15011, "Mechanical General Requirements" and Section 15190, “Mechanical Identification”, applies to this Section, with the additions and modifications specified herein. Plumbing systems including fixtures, equipment, materials,
6.19 15400-6 394.107.001 SECTION 15400
PLUMBING
installation, and workmanship shall be in accordance with the International Plumbing Code and New York State Uniform Code Supplement, except as modified herein. In the Plumbing Code referred to herein, the advisory provisions shall be considered to be mandatory, as though the word "shall" had been substituted for the word "should" wherever it appears. Capacity of equipment shall be not less than that indicated. Plumbing systems shall include all water and sanitary piping buried and aboveground to a limit of 5 feet outside of the building walls unless otherwise specified, or indicated by the Contract Drawings.
1.4 SUBMITTALS:
1.4.1 Manufacturer's Data:
a. Pipe and fittings b. Valves c. Pipe supports (hangers) d. Trench Drains e. Water heaters f. Pumps g. Plumbing fixtures h. Water hammer arresters i. Instantaneous Hot Water Heaters j. Hydropneumatic water tank k. Water storage tank
1.4.2 Certificates of Conformance:
a. Pipe and fittings b. Valves c. Instantaneous Hot Water Heaters d. Water storage tank
1.4.3 Operation and Maintenance Manuals:
a. Trench Drains b. Instantaneous Hot Water Heaters c. Pumps
6.19 15400-7 394.107.001 SECTION 15400
PLUMBING
PART 2 - PRODUCTS
2.1 DWV (DRAIN, WASTE, AND VENT) PIPING: Fittings shall be long radius fittings, except fittings in vent piping may be short radius fittings. Minimum size piping shall be 2 inches for buried piping and 1.5 inches for aboveground piping.
2.1.1 Buried Piping: Buried piping includes piping up to but not more than 6 inches aboveground or floor slab on grade.
2.1.1.1 Cast-Iron Hub and Spigot Pipe and Fittings: ASTM A74 with ASTM C564 or CISPI HSN 85 rubber compression gasket joints, or calked and leaded joints.
2.1.2 Aboveground Piping:
2.1.2.1 Cast-Iron Hubless Pipe and Fittings: CISPI 301 with CISPI 310 coupling joints.
2.1.2.2 Cast-Iron Hub and Spigot Pipe and Fittings: ASTM A74 with ASTM C564 or CISPI HSN 85 rubber compression gasket joints, or calked and leaded joints.
2.1.2.3 Copper Tubing: ASTM B306, with ANSI B16.23, ANSI B16.29, or ANSI B16.32 solder joint fittings using ASTM B32, 95-5 tin-antimony or Grade Sn96 tin-silver solder, and flux containing not more than 0.2 percent lead.
2.1.2.4 Steel Pipe: ASTM A53 or ASTM A120, Schedule 40, hot-dip galvanized, threaded end connections; with ANSI B16.12 hot-dip galvanized threaded fittings.
2.1.3 Cleanouts: ANSI A112.36.2M; provide threaded bronze or thermoplastic cleanout plugs.
2.1.3.1 Floor Cleanouts: Provide cast-iron floor cleanout with flange, adjustable height polished bronze or nickel bronze rim and scoriated floor plate with "CO" cast in the plate, and countersunk screws for installing floor plate flush with finished floor.
2.1.3.2 Wall Cleanouts: Provide polished stainless steel or chromium-plated bronze cover plate and secure to cleanout plug with countersunk screw.
2.1.3.3 Cleanouts Exterior to Buildings: Provide cast-iron cleanouts and countersunk plugs. Provide 24- by 24 by 4-inch thick concrete slab with top 1.0 inch above grade with cleanout located in center of slab.
6.19 15400-8 394.107.001 SECTION 15400
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2.1.4 Drains: ANSI A112.21.1M; provide cast-iron drains and clamping rings for use with membrane waterproofing.
2.1.4.1 Flush Strainer Floor Drains: Provide with double drainage flange, perforated or slotted cast bronze or nickel bronze strainer, adjustable collar, and P-trap. Drains of sizes 2, 3, and 4 inches shall have strainers with minimum free drainage area of 5, 11, and 18 square inches, respectively.
2.1.4.2 Trench Drains: Provide high density polyethylene (HDPE) molded, 0.75% pre-sloped, heavy-duty trench drain system. Trench drain shall be comprised of 80” long by 17” wide modules, 3-1/2-inch radiused self-cleaning bottom, positive mechanical connection at joints, rebar clips, and 4” non-hub molded end outlet connection. Trench drains will include manufacturer’s heavy duty ductile iron grate with continuous concrete anchoring bars and ten (10) 4-inch concrete anchors per module. Grates to be special duty, and shall be secured to frame with integral grate locking bars. Frames and grates shall be Load Class F for special duty, ASTM A36 ductile iron and galvanized conforming to ASTM A123, with load capacity exceeding 200,000 pounds and load bearing area of 45 square inches per foot, H-20 and FAA load rated for extra-heavy loads, slow wide of 3/8 inches and an open area of 20.5 inches/foot. Manufacture of trench drain and grate shall be as by Zurn Model Z874-12-DGF, or equal.
2.2 DOMESTIC WATER PIPING:
2.2.1 Aboveground Piping:
2.2.1.1 Copper Tubing: ASTM B88, Type L, with ANSI B16.18 or ANSI B16.22 solder joint fittings using ASTM B32, 95-5 tin-antimony or grade Sn96 tin-silver solder, and flux containing not more than 0.2% lead, shall be provided for aboveground piping.
2.2.2 Water Valves: Provide valves suitable for minimum of 125 psig and minimum of 180 degrees F hot water. Valves shall have threaded end connections with a union on all but one side of the valve, or solder end connections between bronze valves and copper tubing. Copper alloy and bronze valve body shall be ASTM B61 or ASTM B62 copper alloy. Ball valves may be provided in lieu of gate valves.
2.2.2.1 Gate Valves 2" and Smaller: Class 125, ASTM B62 cast bronze composition body and bonnet, soldered ends, solid disc, copper-silicon alloy stem, brass packing gland, teflon- impregnated packing and malleable hand wheel. Manufacture shall be as by Stockham, Crane, or equal.
6.19 15400-9 394.107.001 SECTION 15400
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2.2.2.2 Ball Valves 2" and Smaller: 600 psi cwp, cast brass bodies, two-position hand levers, replaceable reinforced Teflon seats, conventional port, blow-out proof stems, chrome-plated brass ball, soldered ends with extended solder cups. Manufacture shall be as by Stockham, Crane, Apollo, or equal.
2.2.2.3 Check Valves 2" and Smaller: Class 125, soldered ends, ASTM B62 cast bronze composition bodies and caps and swing disc type. Manufacture shall be as by Stockham, Crane, Powell, or equal.
2.2.3 Hydro-pneumatic Tank: Provide hydro-pneumatic tank, controlled air type with factory pre-charged internal air pressure, 20-40 working pressure, heavy duty butyl bladder with NSF/ANSI 61 approval, and painted with one shop coat of red oxide primer. Tank shall be constructed of welded steel, and tested and stamped in accordance with Section VIII, Division I of the ASME Code for a working pressure of 125 psi and air pre-charged. Tank volume shall be 35 gallons and 10 gallons drawdown at 100 psi maximum working pressure. Provide adjacent 0- 100 psi gauge. Manufacture shall be as by Wessels Model FXT-403, or approved equal.
2.2.3.1 Provide integral pressure switch, single phase, 208V, minimum 10 amp. rated contacts, NEMA 12 enclosure with flexible nitrile-butadiene rubber diaphragm. Switch shall operate as follows: 20 psi cut in, 40psi cut out.
2.2.4 Water Storage Tank: NSF/ANSI 61 certified, FDA approved high density polyethylene 65-gallon vertical white storage tank with 6-inch threaded-vented top fill cap and 3/4-inch polyethylene fitting with o-ring and anti-vortex cap outlet. Tank shall be provided with integral gallon markers. Tank shall be approved for use with potable water. Manufacture shall be as by Snyder Industries, or approved equal.
2.2.5 Pumps: Submit the manufacturer’s certified characteristic performance curve for the impeller size to be furnished. Vertical in-line, multi-stage pressure booster pump, 316 stainless steel shaft, 304 stainless steel impeller chamber and outer sleeve, cast iron pump head, base and oval npt flanges, and cartridge type shaft seal. Manufacture shall be as by Grundfos CR, or approved equal.
2.3 MISCELLANEOUS PIPING MATERIALS:
2.3.1 Pipe Nipples: ANSI B16, copper alloy for use in copper tubing and hot-dip galvanized Schedule 80 steel pipe for use in steel piping.
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2.3.2 Unions: ANSI B16 for use in copper tubing; ANSI B16.39 hot-dip galvanized steel for use in steel piping.
2.2.3 Flanges: ANSI B16.1, Class 125, for use in ferrous piping; ANSI B16.22 or ANSI B16.24 for use in copper tubing; with full face flat type synthetic rubber gaskets.
2.3.4 Escutcheon Plates: One piece or split hinge type metal plates for piping passing through floors, walls, and ceilings in exposed spaces, chromium-plated finish on plates in finished spaces, paint finish on plates in unfinished spaces, and with setscrews or other approved positive means to anchor plates in place securely.
2.3.5 Pipe Sleeves:
2.3.5.1 Sleeves in Masonry and Concrete Walls, Floors, and Roofs: ASTM A53 or ASTM A120, Schedule 40 or Standard Weight, hot-dip galvanized steel pipe sleeves.
2.3.5.2 Sleeves in Partitions and Other Than Masonry and Concrete Walls, Floors, and Roofs: Hot-dip galvanized steel sheet having a nominal weight of not less than 0.90 pounds per square foot.
2.3.6 Pipe Hangers and Supports: Provide MSS SP 58 and MSS SP 69, Type 1 or 6, of the adjustable type, except as modified herein or indicated otherwise. Attachments to steel W or S beams shall be with Type 21, 28, 29, or 30 clamps. Attachments to steel angles and channels (with web vertical) shall be with Type 20 clamp with a beam clamp channel adaptor. Attachments to steel channel web horizontal) shall be with drilled hole on center line and double nut and washer. Attachments to concrete shall be with Type 18 insert or a drilled hole with expansion anchor. Attachments to wood shall be as indicated. Hanger rods and attachments shall be full size of the hanger threaded diameter. Provide Type 40 insulation protection shields for insulated piping. Provide steel support rods. Provide nonmetallic, hair felt, or plastic piping isolators between copper tubing and the hangers.
2.4 FIXTURES, FITTINGS, ACCESSORIES, AND SUPPLIES: Provide control-stop valves in each supply to each fixture. The finish of fittings, accessories, and supplies exposed to view shall be chromium-plated per ANSI A112.18.1M. Center set faucets shall be top-mounted with inlets on not greater than 4-inch centers.
2.4.1 Tank Type Water Closets (P-1): ANSI A112.19.2M, close-coupled, white vitreous china, dual flush pressure assist type, floor-mounted, floor outlet, fully glazed trapway, elongated bowl, white solid plastic elongated open-front seat, and ANSI A112.19.5 trim. Water closet
6.19 15400-11 394.107.001 SECTION 15400
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height shall be no less than 17 inches above finished floor to top of seat. The water flushing volume shall be dual flush with 1.6 gallons or 1.1 gallons per flush. Water closet shall be as manufactured by Kohler Highline, or approved equal.
2.4.2 Lavatories (P-2): ANSI A112.19.2M white vitreous china with ANSI A112.6.1M concealed arm carrier support, straight back type, minimum dimensions of 20 inches wide by 18 inches front to rear, 29 inches minimum clearance from bottom of front rim to floor, 34 inches front rim height above floor. Provide ANSI 112.18.1M chrome plated center set (4-inch on center) faucets, 0.5 GPM vandal resistant, pressure compensating multi-laminar spray 5 inches above rim, stationary spout, ADA compliant lever handles, perforated grid strainers with offset tailpiece, and 1.25-inch adjustable P-trap. Faucets with wrist action handles shall open within one-quarter turn in opposite directions. Provide ANSI A112.6.1M concealed chair carriers. Manufacture shall be as by Kohler, or approved equal.
2.5 INSTANTANEOUS HOT WATER HEATER: UL rated, electric instantaneous hot water heater, replaceable cartridge type element, iron free, nickel chrome material. Maximum operating pressure of 150 psi, and shall be activated at a flowrate of 0.3 gpm. Capacity and performance shall be as scheduled. Heater shall be provided with compression fittings and NEMA 4 enclosure. Manufacture shall be as by Eemax, Model SP35, or approved equal.
PART 3 - EXECUTION
3.1 INSTALLATION: Installation of plumbing systems including fixtures, equipment, materials, and workmanship shall be in accordance with the International Plumbing Code and Regional Amendments, except as modified herein. When fixtures require both hot water and cold water supplies, provide the hot water supply to the left of the cold water supply. Plastic piping shall not penetrate fire walls or fire floors and shall be used on one side of fire walls and fire floors not closer than 6 inches to the penetration.
3.1.1 Threaded Connections: Jointing compound for pipe threads shall be polytetrafluoroethylene (PTFE) pipe thread tape, pipe cement and oil, or PTFE powder and oil; apply only on male threads.
3.1.2 Solder End Valves: Remove stems and washers and other item subject to damage by heat during installation. Reassemble valve after soldering is completed. Valves without heat sensitive parts do not require disassembly but shall be opened at least two turns during soldering.
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3.1.3 Pipe Supports (Hangers): Provide additional supports at the concentrated loads in piping between supports, such as for in-line water pumps and flanged valves.
3.1.3.1 Maximum Spacing Between Supports:
a. Vertical Piping: Support metal piping at each floor, but at not more than 10-foot intervals.
b. Horizontal Piping: Support cast-iron piping at 5-foot intervals, except for pipe exceeding 5-foot length, provide supports at intervals equal to the pipe length but not exceeding 10 feet. Support steel piping and copper tubing as follows:
MAXIMUM SPACING (FEET) Nominal Pipe Size One and Under 1.25 1.5 2 2.5 3 3.5 4 5 6 (Inches) Steel Pipe 7 8 9 10 11 12 13 14 16 17 Copper Tube 6 7 8 8 9 10 11 12 13 14
3.1.4 Ductile Iron Pipe Aboveground: Provide flanged joints.
3.1.5 Installation of Pipe Sleeves: Provide pipe sleeves where piping passes through walls, floors, roofs, and partitions. Secure sleeves in proper position and location during construction. Provide sleeves of sufficient length to pass through entire thickness of walls, floors, roofs, and partitions. Provide not less than 0.25-inch space between exterior of piping or pipe insulation and interior of sleeve. Firmly pack space with insulation, and calk at both ends of the sleeve with plastic waterproof cement which will dry to a firm but pliable mass, or provide a segmented elastomeric seal. Seal both ends of penetrations through fire walls and fire floors to maintain fire resistive integrity with UL listed fill, void, or cavity material. Extend sleeves in floor slabs 3 inches above the finished floor, except sleeves are not required where DWV piping passes through concrete floor slabs located on grade.
3.1.6 Water Hammer Arrestor: Install water hammer arrestor at each plumbing fixture provided with a flush valve. Arrestor shall be located with the individual horizontal supply branch no more than 8 linear feet from the fixture.
3.2 NAMEPLATES: Provide laminated plastic nameplates for equipment, gauges, thermometers, and valves; stop valves in supplies to fixtures will not require nameplates. Laminated plastic shall be 0.125-inch thick melamine plastic, black with white center core.
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Surface shall be a matte finish. All corners shall be square. Accurately align lettering and engrave into the white core. Minimum size of nameplates shall be 1.0 inch by 2.5 inches. Lettering shall be a minimum of 0.25-inch high normal block lettering. Key the nameplates to a chart and schedule for each system. Frame charts and schedules under glass and place where directed near each system. Furnish two copies of each chart and schedule. Each inscription shall identify its function. Equipment nameplates shall show the following information.
a. Manufacturer, type, and model number b. Contract number and accepted date c. Capacity or size d. System in which installed e. System which it controls
3.3 FIELD TESTING: Before final acceptance of the work, test each system as in service to demonstrate compliance with the contract requirements. Perform the following tests in addition to the tests specified in the International Plumbing Code and Uniform Code Supplement of New York State, except as modified herein. Correct all defects in the work provided by the Contractor, and repeat the tests until the work is in compliance with contract requirements. Furnish water, electricity, instruments, connecting devices, and personnel for the tests.
3.3.1 DWV Piping: Before the installation of fixtures, cap the ends of each system, fill the piping with water to the roof, and allow to stand a minimum of 3 hours with no measurable leakage. If the system is tested in sections, each opening shall be plugged and each section tested with not less than a 10-foot head of water.
3.3.2 Domestic Water Piping: Before insulation is applied, hydrostatically test each piping system at not less than 100 psig or working pressure plus 50% ,whichever is greater with no leakage or reduction in gauge pressure for 2 hours.
3.4 DISINFECTION: Thoroughly flush entire system prior to disinfection. Disinfect the new water piping in accordance with AWWA C601. Fill the piping systems with solution containing minimum of 50 parts per million of available chlorine and allow solution to stand for minimum of 24 hours. Maintain a minimum of 25 ppm during retention period. Repeat chlorination as required to achieve 25 ppm minimum. Flush the solution from the systems with clean water until maximum residual chlorine content is not greater than 0.2 parts per million.
6.19 15400-14 394.107.001 SECTION 15400
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PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - PLUMBING:
4.1.1 Measurement for Plumbing shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - PLUMBING:
4.2.1 For Plumbing, not included in other unit or lump sum price items, payment for Plumbing will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 15400-15 394.107.001 SECTION 15486
FUEL STORAGE AND DISPENSING SYSTEMS
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Fuel Storage and Dispensing Systems, as shown on the Plans, as specified and/or directed.
1.2 REFERENCES:
1.2.1 The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1.1 American Petroleum Institute (API) Publications:
SPEC6D Specification for Pipeline and Piping Valves
SPEC12F Specification for Shop Welded Tanks for Storage of Production Liquids
STD 620 Design and Construction of Large, Welded, Low-Pressure Storage Tanks
STD 650 Welded Tanks for Oil Storage RP 652 Linings of Aboveground Petroleum Storage Tank Bottoms
STD 653 Tank Inspection, Repair, Alteration, and Reconstruction
STD 2000 Venting Atmospheric and Low-Pressure Storage Tanks
STD 2350 Overfill Protection for Storage Tanks in Petroleum Facilities
1.2.1.2 American Society for Testing and Materials (ASTM) Publication:
A53 Standard Specification for Pipe, Steel, Black and Hot- Dipped, Zinc-Coated, Welded and Seamless
5.19 15486-1 394.107.001 SECTION 15486
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1.2.1.3 National Fire Protection Association (NFPA) Publication:
17 Dry Chemical Extinguishing Systems
30 Flammable and Combustible Liquids Code
30A Code for Motor Fuel Dispensing Facilities and Repair Garages
1.2.1.4 New York State Codes, Rules and Regulations (NYCRR):
6 NYCRR Part 613 Petroleum Bulk Storage
1.2.1.5 United States Environmental Protection Agency
40 CFR Part 280 Technical Standards and Corrective Action Requirements for Owners and Operators of Underground Storage Tanks (UST)
40 CFR Part 281 Approved Underground Storage Tank Programs
1.2.1.6 International Fire Code:
23 Motor Fuel-Dispensing Facilities and Repair Garages
50 Hazardous Materials – General Provisions
57 Flammable and Combustible Liquids
1.2.1.7 Underwriters Laboratories, Inc. (UL) Publications:
142 Standard for Steel Aboveground Tanks for Flammable and Combustible Liquids
971 Standard for Nonmetallic Underground Piping for Flammable Liquids
971A Standards for Metallic Underground Fuel Pipe
2085 Standard for Protected Aboveground Tanks for Flammable and Combustible Liquids 5.19 15486-2 394.107.001 SECTION 15486
FUEL STORAGE AND DISPENSING SYSTEMS
1.2.1.8 Steel Tank Institute (STI) Publication:
F921 Standard for Aboveground Tanks with Integral Secondary Containment
1.3 GENERAL DESCRIPTION:
1.3.1 Under this Item, Contractor shall provide complete fuel storage and dispensing systems incorporating all necessary components and controls as shown and indicated. These specifications shall govern the installation of complete tank monitoring and fuel management and dispensing systems incorporating all necessary components and controls as shown and indicated. The Contractor shall provide all materials not reused, tools, equipment, labor and incidentals required to provide these systems.
1.4 RELATED WORK:
1.4.1 All earthwork shall be in accordance with Section 02220, "Excavation"; all concrete shall be in accordance with Section 03300, “Cast-In-Place Concrete”, all electrical work shall be in accordance with Division 16, Electrical.
1.5 SUBMITTALS:
1.5.1 Manufacturer's Data, Installation Manuals, Operation and Maintenance Manuals, and Warranty Certificates:
a. Aboveground fuel storage tanks and accessories b. Fuel dispensers and accessories c. Fuel piping d. Fuel pumps and controllers e. Tank monitoring system and accessories f. Fuel management system g. Underground containment sumps h. Underground secondary containment piping i. Spill kits
1.5.2 Fabrication/Erection/Installation Drawings: Shop Drawings and manufacturer installation instructions. Submit design and installation drawings for the following that indicate and detail recommended installation procedures. Shop drawings require review from the Engineer prior to any installation work.
5.19 15486-3 394.107.001 SECTION 15486
FUEL STORAGE AND DISPENSING SYSTEMS
1. Aboveground fuel storage tanks and accessories 2. Fuel dispensers 3. Fuel pumps 4. Fuel piping 5. Tank monitoring system 6. Fuel management system 7. Electrical schematic and conduit routing plan 8. Underground secondary containment piping and sumps
1.5.3 As-Built Drawings: Submit two (2) hard copy sets and one (1) digital file of as-built drawings meeting NYSDEC Certification requirements upon completion of project.
1.5.4 Manufacturer Warranty: Submit warranty registration and written coverage verification from original manufacturer or warranty provider for all system components with manufacturer warranties.
PART 2 - PRODUCTS
2.1 ABOVEGROUND FUEL MONITORING AND DISPENSING SYSTEM:
2.1.1 Aboveground Fuel Storage Tanks and Associated Equipment:
2.1.1.1 Aboveground Fuel Storage Tanks: Provide two (2) factory assembled, aboveground, overfill protected, double-wall steel fuel storage tanks (10,000 gallons diesel fuel, 1,000 gallons gasoline), certified fire resistant and protected against collision and ballistics in accordance with UL 2085, NFPA 30, and NFPA 30A with STI 30-year limited warranty. Tanks shall be compatible with diesel fuel and gasoline. Tanks shall incorporate an interstitial space between the primary tank and secondary tank. The tanks shall be equipped with overfill protection system and integral overfill compartment sized to store a minimum 20% of the tank capacity. The double wall tanks shall be vented and designed such that an overfill of the primary tank is discharged directly into the overfill protection (OP) chamber. The tank exteriors shall be factory painted utilizing a SP 6 blast, epoxy primer, and a white high-solids urethane top coat. The tanks shall be labeled “Flammable” (for gasoline), “Combustible (for Diesel Fuel), “No Smoking” (for all) and with all UL-2085 required labeling. Provide tanks with UL label, product type identification, Owner tank registration number, design and working capacities, fill port product color code and all safety and warning labels required to meet NYSDEC, International Fire Code and NFPA requirements. Provide visual indication labels for the location of the OP compartment on each tank. Manufacture shall be as by Highland Tank (OP Fireguard®), or equal. 5.19 15486-4 394.107.001 SECTION 15486
FUEL STORAGE AND DISPENSING SYSTEMS
2.1.1.1.1 Aboveground Fuel Storage Tank Accessories: Provide fuel storage tanks with lockable stainless steel remote fill stations with minimum 5-gallon capacity containment basin and manual lockable frost-proof drain valve as specified on the Plans. Remote fill station shall include hand pump and accessories to allow transfers of fuel additive to the tank. The tanks shall also include a 3-inch normal atmospheric vents (pressure/vacuum vent for gasoline), sized emergency vents, inlet drop tube, stick port, submersible pump, top mounted clock-type gauge, automatic tank gauge probe, primary and interstitial emergency vents, grounding lug, manway access to primary tank, interstitial leak sensor and overfill protection system, including audible alarm and strobe light activated at 90 percent tank capacity and automatic fill tube shut-off valve activating at 95 percent tank capacity, in accordance with NFPA 30A. Tank shall be constructed with saddle support legs and anchorage. Provide valves and fittings shown on the Plans or required for complete and proper operation of fuel storage tank system. Each OP chamber shall be equipped with 3-inch atmospheric vent, emergency vent and leak sensor to monitor for the presence of petroleum or liquid. Provide a ship ladder with catwalk as shown on the Plans to access tank top and stick port which shall be OSHA compliant. Tank manufacturer shall provide the ship ladder and catwalk as accessories to the aboveground storage tank as indicated on the Plans. Provide access restriction chain on base of ladder.
2.1.2 Fuel Dispensers:
2.1.2.1 Diesel Fuel/Gasoline Remote Dispenser: Provide two (2) new single-product, single- nozzle dispensers, consisting of one nozzle and high-hose retractor for each fuel type. Dispenser shall have a nominal 22 gpm capacity for each diesel fuel nozzle, with minimum 12 feet fueling radius (at grade), 1” inch hardwall dispensing hose with automatic closing type deadman nozzle, breakaway fittings, and double joint hose swivel. Dispenser shall be limited to 10 GPM EPA nozzle flow limit for each gasoline nozzle, with minimum 12 feet fueling radius (at grade), ¾” inch hardwall dispensing hose with automatic closing type deadman nozzle, breakaway fittings, double joint hose swivel, and filters for each product. Dispensers shall be island-mounted and island-oriented with underground containment sumps as indicated on the Plans. Manufacturer shall be as by Wayne (Select Series), or equal.
2.1.2.2 Electronic Register Meter and Remote Dispenser Units: Provide UL listed (Class 1, Division 2) electronic register meter units enclosed within a heavy gauge cabinet with the lower hydraulic cabinet – door panels, base frame, and lower side panels constructed of stainless steel. Units shall include non-volatile electronic control unit/totalizer with backlit LCD display of transaction gallons, dispensed and total gallons, electromechanical non-resettable totalizer, electronic pulse unit, 120 VAC power supply, -30oF to 150oF temperature range electronics heater, hose nozzle holder and all safeties and controls required for the proper dispensing of diesel fuel and gasoline. Units shall include weights and measures accuracy meter, associated piping, valves, controls, safety devices and accessories.
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2.1.2.3 Dispenser Accessories: All dispenser accessories shall be UL listed. Dispensers shall be provided with all necessary hardware and software necessary to interface with the fuel management system for a complete and operational system. Provide each dispenser with reflective labeling for each hose visible from the fuel management system fuel island terminal. Dispenser numbering scheme to be approved by Owner.
2.1.2.4 Manufacturer Warranty: Each dispenser shall be provided with a two (2) year warranty for parts and labor except for cabinet which shall be warranted against corrosion for four (4) years.
2.1.2.5 Submersible Pumping Units: Provide one (1) 1.5 horsepower and one (1) new ¾ horsepower fixed speed submersible turbine pumps for diesel and gasoline fuel, respectively, and control modules as indicated on the Plans and as required for complete and proper operation. Pumps shall be UL listed for operation in hazardous locations (Class 1, Group D atmospheres). Pumps shall supply the minimum flow rates listed above to dispenser when all nozzles are in operation. Pressure line shall be equipped with a mechanical line leak detection system capable of detecting a 3 gallon per hour leak at 10 pounds per square inch line pressure within 1 hour and shall be plumbed to allow for ease of performing annual testing. The leak detection system shall cut off the flow within the fuel supply lines or trigger the audible and visual alarms of the tank monitoring system when a leak is detected. Pumps shall be compatible with gasoline and diesel fuel. Manufacturer shall be as by Red Jacket, or equal.
2.1.2.6 Submersible Pumping Unit Control Module: Provide each pump with a pump controller and dispenser hook interface controller. Manufacturer shall be as by the pump manufacturer (Red Jacket, or equal).
2.1.3 Tank Monitoring System: Provide integrated single control console for the monitoring of product level, product volume with statistical inventory reconciliation, temperature compensated product volume, sump leak sensors, interstitial leak sensors with remote input/output data communication capability and printed output. The storage tank monitoring system shall be provided and installed with all necessary components for the complete and proper operation of the system as shown on the Plans and specified herein.
2.1.3.1 Monitoring System Panel: Provide wall mounted panel with four-line, 40-character backlit LCD display, 20 button keypad, and power and alarm pilot lights. Fix a laminated plastic label identifying “Fuel Storage Tank Monitoring System” to panel. All wiring internal to the panel shall be run in neat bundles secured by wire ties or run in nonmetallic slotted raceways. All internal wiring shall have wire numbers at each termination. Provide solid metal barrier to separate intrinsically safe (IS) wiring from non-IS wiring. Panel shall include numbered terminal strips for connection of field wiring to remote devices. Panel shall include all necessary
5.19 15486-6 394.107.001 SECTION 15486
FUEL STORAGE AND DISPENSING SYSTEMS
mounting hardware for the permanent installation of the monitoring system where indicated on Plans. Panel shall incorporate the following hardware options:
a. Hayes compatible internal fax/modem control module and communication ports for direct I/O communications to fax machine, telephone, and/or remote P/C. b. Control modules for monitoring probes, sensors, and alarms specified herein. c. Dry contact module for panel alarm lights. d. RS-232 serial port. e. RS-485 serial port g. Integral printer. h. Remote high-level alarm horn, strobe, and acknowledgment button for each tank. i. Manufacture shall be OMNTEC OEL 8000 III (Proteus) Series, or equal.
2.1.3.1.1 Tank High Level Alarm: A remote high level alarm horn and strobe shall be provided for each tank as indicated on the Plans. A high-level alarm horn acknowledgment switch shall be provided as indicated. The high level alarm shall signal alarm at 90% tank capacity (tank working capacity). Provide signage at high level alarm that states: “WHEN ALARM SOUNDS TANK HAS REACHED CAPACITY. DO NOT OVERFILL.”
2.1.3.1.2 Provide associated communications software and modules necessary for remote IBM P/C compatible data communications. Communications software shall be capable of translating all data to and from tank monitoring console control module to include product inventory, product height, water height, fuel temperature, leak detection data, sensor status, delivery data, alarm history, system configuration, tank status, and time and date. Communication software shall also be capable of notification by fax, email, and telephone of an alarm condition at the tank monitoring console. The system shall be able to generate reports through the communication interface in a display or printer. All reports may be retrieved locally. Manufacture shall be as by OMNTEC, or equal.
2.1.3.1.3 Tank Level Automatic Tank Gauging (ATG) Probe: Provide each storage compartment with magnetostrictive type level probes for the continuous measurement of product height, water height, and temperature for remote output of gross and temperature compensated volumes. Manufacture shall be as by OMNTEC, or equal.
2.1.3.1.4 Leak Detection Sensors: Provide interstitial space, OP chambers, and secondary containment sumps with discriminating leak detection sensor probes for the detection of water and petroleum. Provide probe and sensor identification drawing at the Tank Monitor Panel. Manufacture shall be as by OMNTEC (Bright Eye Sensors), or equal.
5.19 15486-7 394.107.001 SECTION 15486
FUEL STORAGE AND DISPENSING SYSTEMS
2.1.4 Fuel Management System: The existing fuel management system shall be salvaged during demolition of the existing fuel island and dispenser equipment. The system shall be re- installed with new fuel dispensing equipment and returned to the same functionality as its pre- construction condition.
2.1.4.1 The fuel site controller (FSC) shall be re-installed in coordination with the Owner.
2.1.4.2 The fuel island terminal (FIT) shall be re-installed in coordination with the Owner.
2.1.4.3 The fuel management system shall be configured to utilize the same system access already in-use from the existing fuel management system.
2.1.4.4 Operational Training: As a part of the fuel management system reinstallation, the Contractor shall provide a minimum of one (1) day (8 hours) of operational training.
2.1.5 Fire Extinguishers: Provide and install fire extinguishers in accordance with NFPA 30A and International Fire Code Chapter 23 as indicated on the Plans and as specified. The fire extinguishers have a minimum rating of 2-A:20-B:C and shall be located within 75 feet of all pumps, dispensers, or storage tank openings. Extinguishers shall be provided within a glass storage enclosure and clearly marked “Fire Extinguisher”. Provide additional signage to clearly indicate extinguisher location from all fueling locations.
2.1.6 Spill Kits: Provide oil-only spill kit(s) capable of containing and absorbing a minimum of 52 gallons of spilled gasoline or diesel fuel located at remote fill stations and as indicated on the Plans. Spill kit(s) to be supplied in high-visibility UV protected weather tight containers or weather tight over pack containers with high-visibility UV protective cover. Oil-only spill kits and covers shall be high visibility yellow color and labeled “For Use with Gasoline and Diesel Fuel Spills”. Manufacturer of oil-only spill kit shall be as by PIG, Kit 402, or equal.
PART 3 - EXECUTION
3.1 INSTALLATION:
3.1.1 Aboveground Storage Tank and Piping: Tank and piping systems shall be installed in strict accordance with the manufacturer’s installation instructions and as indicated. Before placing the tank onto the pad, all foreign matter shall be cleaned thoroughly from the pad. Install leveling pads constructed of non-shrink grout for each tank leg. Provide tank anchors as shown on the Plans and as specified by the tank manufacturer. Handle tank during transportation and while lifting in such a manner as to prevent damage to tank. Any damage to the tank or paint as a result of work performed by the Contractor shall be repaired in accordance with manufacturer recommendations. 5.19 15486-8 394.107.001 SECTION 15486
FUEL STORAGE AND DISPENSING SYSTEMS
3.1.2 Signage: All warning and safety signage shall be provided and constructed in compliance with NFPA Chapters 30 & 30A, and International Fire Code Chapters 23, 50 and 57, and any other local, State or Federal requirements. Signage shall be metal backed construction, permanently mounted and of the color and sizes dictated by the applicable code and regulation. The Contractor shall provide signage including, but not limited to the following:
3.1.2.1 Flammable/Combustible Liquid General Requirements:
a. Flammable Liquid General Requirements: Labeling and Signage Style. Durable metal backed construction; white lettering on red background. Letters shall be not less than 3 inches in height and 0.5 inch in stroke. For warning of the hazard of flammable liquids:
“DANGER – FLAMMABLE LIQUIDS” (for gasoline only) “DANGER – COMBUSTIBLE LIQUIDS” (for diesel fuel only)
Location. Post conspicuously on all dispenser areas or as additionally required by code enforcement official. Piping containing flammable liquids shall be identified in accordance with ANSI A13.1.
Identification. Color coding or other approved identification means consistent with Title 6 NYCRR Part 613 shall be provided on each loading and unloading riser for flammable or combustible liquids to identify the contents of the tank served by the riser.
b. Emergency Disconnect Switches. All emergency disconnect switches shall be distinctly labeled as:
“Emergency Fuel Shutoff”
c. Dispensing Operations:
Operating instructions. Dispenser operating instructions shall be conspicuously posted in approved locations on every dispenser and shall indicate the location of the emergency controls.
d. Provide signage with instructions for emergency procedures (respective to facility):
“In Case of Fire, Spill or Release:
1) Use Emergency Pump Shutoff 5.19 15486-9 394.107.001 SECTION 15486
FUEL STORAGE AND DISPENSING SYSTEMS
2) Report The Accident to: Fire Department Telephone No.: 911 New York State Dec Spill Hotline No.: (800) 457-7362 Facility Address: NYS Route 177, Rodman, New York 13682 Facility Name: Development Authority of the North Country Materials Management Facility Phone: (315) 661-3230
e. Warning signs. Posted conspicuously in the sight of each dispenser in the fuel- dispensing area, signage that is metal backed construction, signage warning against the following:
1) “DANGER – COMBUSTIBLE LIQUIDS” 2) “DANGER – FLAMMABLE LIQUIDS” 3) “WARNING” “It is illegal and dangerous to dispense fuel into unapproved containers” “Smoking is prohibited” “The engine shall be shut off during the refueling process” “No filling of portable containers in or on a motor vehicle Place container on ground before filling” “Discharge your static electricity before fueling by touching a metal surface away from the nozzle” “Do not re-enter your vehicle while gasoline is pumping” “If a fire starts do not remove nozzle -- back away immediately” “Do not allow individuals under licensed age to dispense fuel”
f. Hazard identification signs. Unless exempted by the code enforcement official, visible hazard identification signs in accordance with NFPA 704 for the specific material contained shall be placed on all aboveground tanks. The hazard placarding shall include NFPA Hazard Diamond at a minimum. All tanks should also be labeled with fire hazard: “DANGER – FLAMMABLE LIQUIDS” or “DANGER – COMBUSTIBLE LIQUIDS”.
g. Smoking. Smoking shall be prohibited and “No Smoking or Open Flame” signs provided within 25 feet of outdoor storage, dispensing or open use areas.
h. NYSDEC Required Labels on Tank (to be affixed directly on tank) for the following: 1) Color code fill port in accordance with API and NYSDEC for products stored. 2) Label tank with unique tank identification number as listed on the NYSDEC Petroleum Bulk Storage Registration on the tank and at the gauge.
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FUEL STORAGE AND DISPENSING SYSTEMS
3) Label Tanks with Design Capacity or Working Capacity at the tank gauge and fill port. Include a conversion chart from depth of product (in inches and feet) to gallons. 4) Label Tanks with products stored.
i. NYSDEC Required Labels at remote fill ports: 1) Color code fill port in accordance with API and NYSDEC for products stored. 2) Sign that includes the identification number as listed on the NYSDEC Petroleum Bulk Storage Registration, tank Design and Working Capacity, conversion chart from depth of product (in inches and feet) to gallons, and Product Stored (one sign per remote fill port). 3) Label Tanks with Design Capacity or Working Capacity at the tank gauge and fill port. Include a conversion chart from depth of product (in inches and feet) to gallons. 4) Label Tanks with products stored.
j. Transfer Containment Area: Mount sign at remote fill station :
“PRIOR TO FUEL DELIVERY: • FOLLOW FACILITY FUELING PROCEDURES, • ENSURE CONTAINMENT VALVE CLOSED PRIOR TO DELIVERY, • CHECK ALL HOSE CONNECTIONS, • REPORT ANY SPILLS IMMEDIATELY”
k. Provide identification and response procedure labels for all alarms, horns, strobes, and monitoring systems.
3.1.3 Fuel Pumping Dispensers: Fuel dispensers shall be provided, complete with piping and equipment. Electrical connections shall be in accordance with Section 16011 “Electrical General Requirements. Follow manufacturer’s recommendations for installation and initial startup.
3.1.4 Fuel Control Equipment: Install all equipment in accordance with Section 16011 "Electrical General Requirements" and per manufacturer's recommendations. For initial startup of all fuel control equipment, appropriate factory authorized representatives shall be present to calibrate and check all systems for operational status at no additional cost to the Owner. Factory authorized representatives shall also instruct Owner as to operational procedures and maintenance schedule.
5.19 15486-11 394.107.001 SECTION 15486
FUEL STORAGE AND DISPENSING SYSTEMS
3.1.5 Storage Tank Monitoring and Fuel Management System Equipment: Install all monitoring and management equipment in strict accordance with the manufacturer's recommendations. Installation of the monitoring equipment shall be conducted by a manufacturer certified technician. Electrical wiring and connections shall be in accordance with Section 16011, "Electrical General Requirements". Following installation, programming, troubleshooting, and startup of installed systems, provide a minimum of 8 hours of training for the operation of tank monitor system and an additional 8-hours of training for the operation, programming, and reporting features of the fuel management systems by factory authorized technicians.
3.1.6 Equipment Start-Up: The Contractor shall start up and operate the new equipment systems under direct responsibility and supervision of the manufacturer, and in the presence of the Owner’s representative. The Contractor shall provide all labor, equipment and materials that are required to facilitate the new equipment start-up and initial operation. The Contractor, under the direction of the respective manufacturer’s representative, shall perform all work of placing into operation all equipment systems provided by him, except as specifically noted otherwise. Make all adjustments to equipment that are necessary to assure proper operation as instructed by the manufacturer of the equipment.
3.1.7 Warranty: All fuel storage systems equipment shall be warranted for a period of not less than two (2) years from acceptance date.
END OF SECTION
5.19 15486-12 394.107.001 SECTION 15492
FUEL GAS PIPING
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Fuel Gas Piping, as shown on the Plans, as specified and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American National Standards Institute, Inc. (ANSI) Publications:
B1.1 Unified Screw Threads
B1.20.1 Pipe Threads, General Purpose (Inch)
B16.3 Malleable Iron Threaded Fittings
B16.5 Pipe Flanges and Flanged Fittings
B16.9 Factory-Made Wrought Steel Butt Welding Fittings
B16.11 Forged Steel Fittings, Socket-Welding and Threaded
B16.33 Manually Operated Metallic Gas Valves for use in Gas Piping Systems up to 125 psig (Sizes 1/2 through 2)
B16.38 Large Metallic Valves for Gas Distribution (Manually Operated, NPS 2-1/2 to 12, 125 psig Maximum)
B16.39 Malleable Iron Threaded Pipe Unions Classes 150, 250, and 300
B16.40 Manually Operated Thermoplastic Gas Shutoffs and Valves in Gas Distribution Systems
4.19 15492-1 394.107.001 SECTION 15492
FUEL GAS PIPING
B18.2.1 Square and Hex Bolts and Screws Inch Series Including Hex Cap Screws and Lag Screws
B18.2.2 Square and Hex Nuts (Inch Series)
B31.8 Gas Transmission and Distribution Piping Systems
Z21.41 Quick-Disconnect Devices for Use with Gas Fuel
Z21.45 Flexible Connectors of Other Than All-Metal Construction for Gas Appliances
Z21.69 Connectors for Movable Gas Appliances
Z21.70 Earthquake Actuated Automatic Gas Shutoff Systems
1.2.2 American Society for Testing and Materials (ASTM) Publications:
A53 Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless
A193 Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service
A194 Carbon and Alloy Steel Nuts for Bolts for High-Pressure and High-Temperature Service
D2513 Thermoplastic Gas Pressure Pipe, Tubing, and Fittings
D2683 Socket-Type Polyethylene Fittings for Outside Diameter-Controlled Polyethylene Pipe and Tubing
1.2.3 American Society of Mechanical Engineers (ASME) Publication:
BPVSEC8 Boiler and Pressure Vessel Code, Division 1 Rules for Construction of Pressure Vessels
4.19 15492-2 394.107.001 SECTION 15492
FUEL GAS PIPING
1.2.4 Code of Federal Regulations (CFR) Publications:
49 PT 192 Transportation of Natural and Other Gas by Pipeline: Minimum Federal Supply Standards
49 PT 195 Transportation of Hazardous Liquids by Pipeline
1.2.5 Manufacturers Standardization Society of the Valve and Fittings Industry (MSS) Publications:
SP 58 Pipe Hangers and Supports - Materials, Design, and Manufacture
SP 69 Pipe Hangers and Supports - Selection and Application
SP 89 Pipe Hangers and Supports - Fabrication and Installation Practices
1.2.6 National Fire Protection Association (NFPA) Publications:
54 National Fuel Gas Code
58 Liquified Petroleum Gas Code
1.3 RELATED REQUIREMENTS: Section 09900, “Painting”, Section 15011, "Mechanical General Requirements", and Section 15190, “Mechanical Identification”, applies to this Section, with additions and modifications specified herein.
1.4 SUBMITTALS: Submit the following:
1.4.1 Manufacturer's Catalog Data:
a. Pipe and fittings
b. Valves
c. Hangers and supports
4.19 15492-3 394.107.001 SECTION 15492
FUEL GAS PIPING
d. Pressure regulator
e. Gas equipment connectors
f. LPG containers and accessories
1.4.2 Certificates of Compliance:
a. LPG containers and accessories
1.5 QUALITY ASSURANCE:
1.5.1 Welder's Qualifications: Comply with ANSI B31.8. The steel welder shall have a copy of a certified ANSI B31.8 qualification test report. Contractor shall also conduct a qualification test. Submit each welder's assigned number, letter, or symbol used to identify work of the welder. Affix symbols immediately upon completion of welds. Welders making defective welds after passing a qualification test shall be given a requalification test and, upon failing to pass this test, shall not be permitted to work this Contract.
1.5.2 Safety Standards: 49 CFR PT 192.
1.6 DELIVERY, STORAGE, AND HANDLING: Handle, transport, and store plastic pipe and fittings carefully. Plug or cap pipe ends during transportation or storage to minimize dirt and moisture entry. Do not subject to abrasion or concentrated external loads. Discard PE pipe sections and fittings that have been damaged.
PART 2 - PRODUCTS
2.1 MATERIALS AND EQUIPMENT: Conform to NFPA 54 and NFPA 58 with requirements specified herein. Supply piping to appliances or equipment shall be at least as large as the inlets thereof.
2.2 PIPE AND FITTINGS:
2.2.1 Aboveground and Within Buildings and Vaults:
4.19 15492-4 394.107.001 SECTION 15492
FUEL GAS PIPING
a. Pipe: Black steel in accordance with ASTM A53, Schedule 40, threaded ends for sizes 2 inches and smaller; otherwise, plain end beveled for butt welding.
b. Threaded Fittings: ANSI B16.3, black malleable iron.
c. Socket-Welding Fittings: ANSI B16.11, forged steel.
d. Butt Welding Fittings: ANSI B16.9, with backing rings of compatible material.
e. Unions: ANSI B16.39, black malleable iron.
f. Flanges and Flanged Fittings: ANSI B16.5 steel flanges or convoluted steel flanges conforming to ASME BPVSEC8. Flange faces shall have integral grooves of rectangular cross sections which afford containment for self-energizing gasket material.
2.3 SHUTOFF VALVES, ABOVEGROUND: Provide lockable valves where indicated.
2.3.1 Shutoff Valves, Sizes Larger Than 2 Inches: Cast-iron body plug valve in accordance with ANSI B16.38, non-lubricated, wedge-mechanism or tapered lift plug, and flanged ends.
2.3.2 Shutoff Valves, Sizes 2 Inches and Smaller: Bronze body plug valve in accordance with ANSI B16.33, straightway, taper plug, regular pattern with a port opening at least equal to the internal pipe area or round port full bore pattern, non-lubricated, PTFE packing, flat or square head stem with lever operator, 125 psig rating, threaded ends.
2.3.3 Pressure Regulator: Self-contained with spring-loaded diaphragm pressure regulator, psig to inches water reduction, pressure operating range as required for the pressure reduction indicated, volume capacity not less than indicated, and threaded ends for sizes 2 inches and smaller, otherwise flanged.
2.4 GAS EQUIPMENT CONNECTORS:
a. Flexible Connectors: ANSI Z21.45.
b. Quick Disconnect Couplings: ANSI Z21.41.
c. Semi-Rigid Tubing and Fittings: ANSI Z21.69.
4.19 15492-5 394.107.001 SECTION 15492
FUEL GAS PIPING
2.5 HANGERS AND SUPPORTS: MSS SP58, as required by MSS SP69.
2.6 WELDING FILLER METAL: ANSI B31.8.
2.7 PIPE-THREAD TAPE: Anti-seize and sealant tape of polytetrafluoroethylene (PTFE).
2.8 BOLTING (BOLTS AND NUTS): Stainless steel bolting; ASTM A193, Grade B8M or B8MA, Type 316, for bolts; and ASTM A194, Grade 8M, Type 316, for nuts. Dimensions of bolts, studs, and nuts shall conform with ANSI B18.2.1 and ANSI B18.2.2 with coarse threads conforming to ANSI B1.1, with Class 2A fit for bolts and studs and Class 2B fit for nuts. Bolts or bolt-studs shall extend through the nuts and may have reduced shanks of a diameter not less than the diameter at root of threads. Bolts shall have American Standard regular square or heavy hexagon heads; nuts shall be American Standard heavy semi-finished hexagonal.
2.9 GASKETS: Fluorinated elastomer, compatible with flange faces.
2.10 IDENTIFICATION FOR ABOVEGROUND PIPING: Section 15190, “Mechanical Identification” and as required by NFPA 54 and NFPA 58.
2.11 LIQUIFIED PETROLEUM GAS (LPG) ACCESSORIES: Provide piping and fittings, hose and flexible hose connectors, strainer, and marking conforming to NFPA 58.
PART 3 - EXECUTION
3.1 INSTALLATION: Install and store liquified petroleum gas piping, appliances, and equipment in accordance with NFPA 54 and NFPA 58.
3.1.1 Piping: Cut pipe to actual dimensions and assemble to prevent residual stress. Within buildings, run piping parallel to structure lines and conceal in finished spaces. Terminate each vertical supply pipe to burner or appliance with tee, nipple and cap to form a sediment trap. To supply multiple items of gas-burning equipment, provide manifold with inlet connections at both ends.
3.1.1.1 Cleanliness: Clean inside of pipe and fittings before installation. Blow lines clear using 80 to 100 psig clean dry compressed air. Rap steel lines sharply along entire pipe length before blowing clear. Cap or plug pipe ends to maintain cleanliness throughout installation.
4.19 15492-6 394.107.001 SECTION 15492
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3.1.1.2 Aboveground Steel Piping: Determine and establish measurements for piping at the job site and accurately cut pipe lengths accordingly. For 2-inch diameter and smaller, use threaded or socket-welded joints. For 2-1/2 inch diameter and larger, use flanged or butt welded joints.
a. Threaded Joints: Where possible, use pipe with factory-cut threads, otherwise cut pipe ends square, remove fins and burrs, and cut taper pipe threads in accordance with ANSI B1.20.1. Provide threads smooth, clean, and full-cut. Apply anti-seize paste or tape to male threads portion. Work piping into place without springing or forcing. Backing off to permit alignment of threaded joints will not be permitted. Engage threads so that not more than three threads remain exposed. Use unions for connections to valves for which a means of disconnection is not otherwise provided.
b. Welded Joints: Weld by the shielded metal-arc process, using covered electrodes and in accordance with procedures established and qualified in accordance with ANSI B31.8.
c. Flanged Joints: Use flanged joints for connecting welded joint pipe and fittings to valves to provide for disconnection. Install joints so that flange faces bear uniformly on gaskets. Engage bolts so that there is complete threading through the nuts and tighten so that bolts are uniformly stressed and equally torqued.
d. Pipe Size Changes: Use reducing fittings for changes in pipe size. Size changes made with bushings will not be accepted.
e. Painting: Paint new ferrous metal piping, including supports, in accordance with Section 09900, "Painting". Do not apply paint until piping tests have been completed.
f. Identification of Piping: Identify piping above ground in accordance with Section 15190, “Mechanical Identification”.
3.1.2 Valves: Install valves approximately at locations indicated. Orient stems vertically, with operators on top, or horizontally.
3.1.2.1 Pressure Regulator: Provide plug cock ahead of regulator. Install regulator outside of building and 18 inches above ground on riser. On outlet side of regulator, provide a union and a 3/8-inch gauge tap with plug.
4.19 15492-7 394.107.001 SECTION 15492
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3.1.2.2 Stop Valve and Shutoff Valve: Provide stop valve on service branch at connection to main and shut-off valve on riser outside of building.
3.1.3 Pipe Sleeves: Where piping penetrates concrete or masonry wall, floor or firewall, provide pipe sleeve poured or grouted in place. Make sleeve of steel or cast-iron pipe of such size to provide 1/4-inch or more annular clearance around pipe. Extend sleeve through wall or slab and terminate flush with both surfaces. Pack annular space with oakum, and caulk at ends with silicone construction sealant.
3.1.4 Piping Hangers and Supports: Selection, fabrication, and installation of piping hangers and supports shall conform with MSS SP 69 and MSS SP 89, unless otherwise indicated.
3.1.5 Final Connections: Make final connections to equipment and appliances using rigid pipe and fittings.
3.2 FIELD QUALITY CONTROL:
3.2.1 Metal Welding Inspection: Inspect for compliance with NFPA 54 and NFPA 58. Replace, repair, and then reinspect defective welds.
3.2.2 Pressure Tests: Use test pressure of 1-1/2 times maximum working pressure, but in no case less than 50 psig. Do not test until every joint has set and cooled at least 8 hours at temperatures above 50 degrees F. Conduct testing before backfilling; however, place sufficient backfill material between fittings to hold pipe in place during tests. Test system gas tight in accordance with NFPA 54 and NFPA 58. Use clean dry air or inert gas, such as nitrogen or carbon dioxide, for testing. Systems which may be contaminated by gas shall first be purged as specified. Make tests on entire system or on sections that can be isolated by valves. After pressurization, isolate entire piping system from sources of air during test period. Maintain test pressure for at least 8 hours between times of first and last reading of pressure and temperature. Take first reading at least one hour after test pressure has been applied. Do not take test readings during rapid weather changes. Provide temperature same as actual trench conditions. There shall be no reduction in the applied test pressure other than that due to a change in ambient temperature. Allow for ambient temperature change in accordance with the relationship PF + 14.7 = (P1 + 14.7) (T2 + 460) / T1 + 460), in which "T" and "PF" represent Fahrenheit temperature and gauge pressure, respectively, subscripts "1" and "2" denote initial and final readings, and "PF" is the calculated final pressure. If "PF" exceeds the measured final pressure (final gauge reading) by 1/2 psi or more, isolate sections of the piping system, retest each section individually, and apply a solution of warm soapy water to joints of each section for which a
4.19 15492-8 394.107.001 SECTION 15492
FUEL GAS PIPING
reduction in pressure occurs after allowing for ambient temperature change. Repair leaking joints and repeat test until no reduction in pressure occurs. In performing tests, use a test gauge calibrated in one-psi increments and readable to 1/2 psi.
3.2.3 System Purging: After completing pressure tests, and before testing a gas contaminated line, purge line with nitrogen at junction with main line to remove all air and gas. Clear completed line by attaching a test pilot fixture at capped stub-in line at building location and let gas flow until test pilot ignites. Procedures shall conform to NFPA 54 and NFPA 58.
-CAUTION-
Failure to purge may result in explosion within line when air-to-gas is at correct mixture.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - FUEL GAS PIPING:
4.1.1 Measurement for Fuel Gas Piping shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - FUEL GAS PIPING:
4.2.1 For Fuel Gas Piping, not included in other unit or lump sum price items, payment for Fuel Gas Piping will be made at the applicable price stated in the Bid.
END OF SECTION
4.19 15492-9 394.107.001 SECTION 15495
FUEL PIPING
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Diesel Fuel, Gasoline, and Biodiesel (up to B20) as shown on the Plans, and specified.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American National Standards Institute, Inc./American Society of Mechanical Engineers (ANSI/ASME) Publications:
A13.1 Scheme for the Identification of Piping Systems
B1.1 Unified Inch Screw Threads
B1.20.1 Pipe Threads, General Purpose, Inch
B16.3 Malleable Iron Threaded Fittings Classes 150 and 300
B16.5 Pipe Flanges and Flanged Fittings
B16.9 Factory-Made Wrought Buttwelding Fittings
B16.11 Forged Fittings, Socket-Welding and Threaded
B16.39 Malleable Iron Threaded Pipe Unions Classes 150, 250, and 300
B18.2.1 Square, Hex, Heavy Hex, and Askew Head Bolts and Hex, Heavy Hex, Hex Flange, Lobed Head, and Lag Screws (Inch Series)
B18.2.2 Nuts for General Applications: Machine Screw Nuts, Hex, Square, Hex Flange, and Coupling Nuts (Inch Series)
B31.8 Gas Transmission and Distribution Piping Systems
B31.9 Building Services Piping
5.19 15495-1 394.107.001 SECTION 15495
FUEL PIPING
1.2.2 American Society for Testing and Materials (ASTM) Publications:
A53 Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless
A126 Gray Iron Castings for Valves, Flanges, and Pipe Fittings
A181 Forgings, Carbon Steel, for General Purpose Piping
A193 Alloy-Steel and Stainless Steel Bolting Materials for High- Temperature Service
A194 Carbon and Alloy Steel Nuts for Bolts for High-Pressure and High-Temperature Service
A234 Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures
A307 Carbon Steel Externally Threaded Standard Fasteners
1.2.3 Code of Federal Regulations (CFR) Publications:
49 PT 192 Transportation of Natural and Other Gas by Pipeline: Minimum Federal Supply Standards
49 PT 195 Transportation of Hazardous Liquids by Pipeline
1.2.4 Manufacturers Standardization Society of the Valve and Fittings Industry (MSS) Publications:
SP 58 Pipe Hangers and Supports - Materials, Design, and Manufacture
SP 69 Pipe Hangers and Supports - Selection and Application
SP 83 Carbon Steel Pipe Unions - Socket Welding and Threaded
SP 89 Pipe Hangers and Supports - Fabrication and Installation Practices
5.19 15495-2 394.107.001 SECTION 15495
FUEL PIPING
1.2.5 Military Standard (MIL-STD):
101 Color Code for Pipelines and for Compressed Gas Cylinders
1.2.6 National Fire Protection Association (NFPA) Publications:
30 Flammable and Combustible Liquids Code
30A Motor Fuel Dispensing and Repair Garages
1.2.7 New York State Building Code:
International Mechanical Code International Fire Code
1.2.8 Underwriters Laboratories, Inc. (UL) Publications:
971 Standard for Nonmetallic Underground Piping for Flammable Liquids
971A Standard for Metallic Underground Fuel Pipe
1.2.9 New York State Codes, Rules and Regulations (NYCRR):
6 NYCRR Part 613 Petroleum Bulk Storage
1.3 RELATED REQUIREMENTS: Section 15011, "Mechanical General Requirements", applies to this Section, with additions and modifications specified herein.
1.4 SUBMITTALS: Submit the following.
1.4.1 Manufacturer's Catalog Data:
a. Pipe and fittings b. Hangers and supports c. Equipment connectors d. Valves e. Warning tape f. Risers
5.19 15495-3 394.107.001 SECTION 15495
FUEL PIPING
g. Transition fittings h. Secondary containment piping and accessories i. Leak detection equipment and systems
1.4.2 Statements:
a. Welders' qualifications b. Welders' identification symbols/Identification Card
Submit a copy of a certified ANSI B31.8 qualification test report for each welder and welding operator. Submit the assigned number, letter, or symbol that will be used in identifying the work of each welder.
1.4.3 Certificates of Compliance:
a. Transition fittings
b. Compatibility statement from manufacturer for biodiesel.
1.4.4 Installation Documentation:
a. Completed Warranty Certification Card b. Welding Report c. Pressure Test Report for all piping d. Leak Test Report (Underground Sumps)
1.5 QUALITY ASSURANCE:
1.5.1 Welder's Qualifications: Comply with ANSI B31.9. The steel welder shall have a copy of a certified ANSI B31.9 qualification test report. The polyethylene (PE) welder shall have a certificate from a PE pipe manufacturer's sponsored training course. Contractor shall also conduct a qualification test. Submit each welder's assigned number, letter, or symbol used to identify work of the welder. Affix symbols immediately upon completion of welds. Welders making defective welds after passing a qualification test shall be given a requalification test and, upon failing to pass this test, shall not be permitted to work this Contract.
1.5.2 The Contractor shall obtain a hot work permit for all welding or other hot work. A copy of the hot work permit shall be submitted to the Engineer prior to performing any hot work.
1.5.3 Safety Standards: 49 CFR PT 192 and 49 CFR PT 195.
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1.6 DELIVERY, STORAGE, AND HANDLING: Handle, transport, and store equipment, pipe and fittings carefully as directed by manufacturer. Plug or cap pipe ends during transportation or storage to minimize dirt and moisture entry. Do not subject to abrasion or concentrated external loads. Discard PE pipe sections and fittings that have been damaged.
PART 2 - PRODUCTS
2.1 MATERIALS AND EQUIPMENT: Materials, equipment and devices shall, as a minimum, meet all applicable requirements of UL, NFPA, and Fire and Mechanical Code of New York State.
2.2 PIPE AND FITTINGS:
2.2.1 Underground: Provide secondary containment piping system with leak detection as follows:
2.2.1.1 Underground Containment Piping System: Provide UL 971 listed high density polyethylene secondary containment fuel piping system. Both the primary and secondary pipes shall be UL 971 listed. All underground containment piping shall be UL listed for use with gasoline and diesel fuel. Manufacturer shall be as by Advantage Earth Products, Inc., or equal.
2.2.1.2 Aboveground Storage Tank transition sumps shall be an HDPE sump with fiberglass top. Manufacturer shall be as by OPW (PST-4630), or equal.
2.2.1.3 Dispenser sumps shall be one piece HDPE sumps. Dispenser sumps shall be fuel and watertight and provide secondary containment for dispenser and secondary containment piping. Manufacturer shall be as by OPW (Flexworks), or equal.
2.2.1.4 No rubber gaskets or seals shall be permitted on any connection. All sump entry fittings shall be welded to both the sump and the pipe to form a uniform system free of leaks.
2.2.1.5 No underground electrical conduit shall be permitted into sumps. All sump entry fittings shall be welded to both the sump and the pipe to form a uniform system free of leaks.
2.2.1.6 Provide leak detection sensors as stated in Section 15486, “Fuel Storage and Dispensing Systems”.
2.2.2 Aboveground Fuel Fill and Supply:
a. Pipe: Black steel in accordance with ASTM A53, Schedule 40, plain end beveled butt welded.
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b. Socket-Welding Fittings: ANSI B16.11, forged steel. c. Butt Welding Fittings: ANSI B16.9, with backing rings of compatible material. d. Unions: ANSI B16.39, black malleable iron.
2.2.3 Aboveground Tank Vent: Provide vent and other miscellaneous (non-fuel containing) piping as follows:
a. Pipe: Galvanized steel in accordance with ASTM A53, Schedule 40, threaded, flanged, or welded ends for sizes 2 inches and smaller; otherwise, plain end beveled butt welded or flanged connections. b. Threaded Fittings: ANSI B16.3, galvanized malleable iron. c. Socket-Welding Fittings: ANSI B16.11, forged steel. d. Butt Welding Fittings: ANSI B16.9, with backing rings of compatible material. e. Unions: ANSI B16.39, galvanized malleable iron. f. Flanges and Flanged Fittings: ANSI B16.5 steel flanges or convoluted steel flanges conforming to ASME BPVSEC8. Flange faces shall have integral grooves of rectangular cross sections which afford containment for self-energizing gasket material.
2.3 VALVES, ABOVEGROUND:
2.3.1 Ball Valves: Provide MSS SP-110 Class 150 brass, two-piece body, full-port ball valve with union bonnet, blow-out proof stem, hard chrome-plated ball, Teflon seals, and threaded ends. Valve shall be specifically listed for use with intended service and piping system indicated on Plans and this Specification. Manufacture shall be as by Morrison Bros. Co. (Model 691), or equal.
2.3.2 Solenoid Valves: Brass body, Viton® seals, two-way single directional solenoid valve with built-in pressure relief. Solenoid housed in an integral water-tight, explosion proof shell. Valves shall be compatible with the intended service and usage. Provide line strainer as recommended by manufacturer. Valves shall be as manufactured by Morrison Brothers Co. (Model 710), or equal.
2.3.3 Emergency Shut-Off Valves: Cast iron body, corrosion resistant internal components compatible with the stored product, double-poppeted valve with 165 degree Fahrenheit fusible link to shut off fuel flow in the event of a fire. Valve shall also provide impact protection such that no product is spilled in the event of a collision. Contractor shall provide manufacturer recommended anchor kit and hardware. Manufacturer shall be as by OPW (10 Plus Series), or equal.
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2.3.4 Check Valves: Provide inline swing check valve with ductile iron valve body, ductile iron seat ring, Viton® disc, and iron cap. Seat and disc shall be renewable. Valve shall be specifically listed for use with intended service and piping system indicated on Plans and this Specification. Valve shall be as manufactured by Morrison Brothers Co. (246A).
2.4 EQUIPMENT CONNECTORS:
2.4.1 Flexible Connectors: Provide stainless steel flexible connectors as indicated or where necessary. Flexible connectors shall have at least one swivel and shall be constructed of 322 stainless steel hose with 304 stainless steel braid, schedule 80 stainless steel fittings with Viton®/Buna Seals. Connector shall be UL listed for the intended product and use.
2.5 HANGERS AND SUPPORTS: MSS SP 58, as required by MSS SP 69.
2.6 WELDING FILLER METAL: ANSI B31.8.
2.7 PIPE-THREAD SEALANT: Anti-seize and thread sealant with polytetrafluoroethylene (PTFE). Shall be compatible with gasoline, diesel fuel, ethanol (E85), and biodiesel (B5). Manufacturer shall be as by Gasoila (E-Seal), or equal.
2.8 BOLTING (BOLTS AND NUTS): Stainless steel bolting; ASTM A193, Grade B8M or B8MA, Type 316, for bolts; and ASTM A194, Grade 8M, Type 316, for nuts. Dimensions of bolts, studs, and nuts shall conform with ANSI B18.2.1 and ANSI B18.2.2 with coarse threads conforming to ANSI B1.1, with Class 2A fit for bolts and studs and Class 2B fit for nuts. Bolts or bolt-studs shall extend through the nuts and may have reduced shanks of a diameter not less than the diameter at root of threads. Bolts shall have American Standard regular square or heavy hexagon heads; nuts shall be American Standard heavy semi-finished hexagonal.
2.9 GASKETS: Fluorinated elastomer, compatible with flange faces and fuels stored/transmitted.
2.10 PAINT FOR FUEL PIPING SYSTEM: Paint all new piping in accordance with Section 09900, “Painting”. Color to be per ANSI Standards.
PART 3 - EXECUTION
3.1 INSTALLATION: Install fuel piping and equipment in accordance with 6 NYCRR Part 613, NFPA 30 and 30A, the International Fire and Mechanical Codes, and the manufacturer’s instructions.
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3.1.1 Excavating and Backfilling: Perform excavating and backfilling of pipe trench as specified in Section 02220, "Excavation”. Upon excavation, install new piping trench, as indicated. Concrete work and associated items shall be provided in accordance with Section 03300, “Cast-in-Place Concrete”. Coordinate provision of utility warning and identification tape with backfill operation. Bury utility warning and identification tape with printed side up at a depth of 12 inches below the top surface of earth or the top surface of the subgrade under pavements.
3.1.2 Piping: Cut pipe to actual dimensions and assemble to prevent residual stress.
3.1.2.1 Cleanliness: Clean inside of pipe and fittings before installation. Blow lines clear using 80 to 100 psig clean dry compressed air. Rap steel lines sharply along entire pipe length before blowing clear. Cap or plug pipe ends to maintain cleanliness throughout installation.
3.1.2.2 Underground Secondary Containment System: Provide secondary containment fuel pipe to locations as indicated. Prior to installation, obtain printed instructions, training, and technical assistance in proper installation techniques from manufacturer. The Contractor shall obtain the services of a competent manufacturer’s representative to supervise Contractor’s personnel during the start of the installation. Piping shall be one continuous length with no joints or connections underground. All piping joints between UL 971 piping systems are to be electrofusion welded. All fittings, valves, welds, and other connections shall be installed within underground sumps that are accessible at grade. Piping shall be sloped as indicated at a minimum 1% gradient and as recommended by the manufacturer with no siphon traps or wells. The minimum bend radius shall be in accordance with the pipe Manufacturer’s recommendations.
3.1.2.3 Aboveground Primary Steel Piping: Determine and establish measurements for piping at the job site and accurately cut pipe lengths accordingly. For 2-inch diameter and smaller, use socket-welded joints. For 2-1/2 inch diameter and larger, use butt welded joints.
a. Welded Joints: Weld by the shielded metal-arc process using covered electrodes and in accordance with procedures established and quantified in accordance with ANSI B31.8. b. Pipe Size Changes: Use reducing fittings for changes in pipe size. Size changes made with bushings will not be accepted. c. Identification of Piping: Identify piping above ground in accordance with MIL-STD-101, using adhesive backed or snap on plastic labels and arrows. In lieu of labels, identification tags may be used. Apply labels or tags to finished paint at intervals of not more than 50 feet. Provide two copies of the piping identification code framed under glass and install where directed.
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d. Flammable Liquids: Label piping containing flammable liquids in accordance with ANSI A13-1.
3.1.3 Valves: Install valves approximately at locations indicated. Orient stems vertically, with operators on top, or horizontally. Mount with stems at 45 degrees from vertical where operation and serviceability will benefit. For threaded end valves, provide union adjacent to valve on downstream side.
3.1.4 Piping Hangers and Supports: Selection, fabrication, and installation of piping hangers and supports shall conform with MSS SP 69 and MSS SP 89, unless otherwise indicated.
3.2 FIELD QUALITY CONTROL:
3.2.1 Field Tests for Primary Containment Piping: Primary piping system shall be hydrostatically tested at 150 percent of the system design pressure but at least 50 psig with water not exceeding 100 degrees F, for a period of one hour. Before tests, remove or isolate gauges and other apparatus in the new system which may be damaged by high pressure. Repair leaks. Do not caulk joints. Install a calibrated, test pressure gauge in the system to observe loss in pressure. Maintain the required test pressure for a sufficient amount of time to enable an inspection of joints and connections. Correct defects disclosed by the test. Consult manufacturer’s recommendations for further piping specific information.
3.2.2 Field Tests for Secondary Containment Piping: Pneumatically test all secondary containment piping in accordance with the manufacturer’s recommendations. Piping incorporating compressible seal type containment terminations shall be tested at a minimum pressure of 2 psig for a period of not less than an hour.
3.2.3 Startup and Operational Tests: Startup and initially operate the system. During this time, observe the operation of the system and correct any defects or abnormalities which may occur in the overall system.
3.3 WARRANTY: All underground containment piping systems shall be warranted against defects, leakage, and water intrusion by the manufacturer for a period of not less than thirty (30) years for materials. The Contractor shall warrant the installation of underground containment piping systems against leakage, water intrusion, and defects for a period of not less than five (5) years from the acceptance date. All other fuel piping systems shall be warranted for a period of not less than two (2) years for labor and materials from the acceptance date.
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AIR HANDLING AND DISTRIBUTION EQUIPMENT
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Air Handling and Distribution Equipment, as shown on the Plans, as specified and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 Air Movement and Control Association, Inc. (AMCA) Publications:
210 Laboratory Method of Testing Fans for Rating
220 Test Method for Air Curtain Units
300 Reverberant Room Method for Sound Testing of Fans
1.2.2 American National Standards Institute, Inc. (ANSI) Publication:
Z21.47 Gas-Fired Central Furnaces (Except Direct Vent and Separated Combustion System Central Furnaces)
1.2.3 Air-Conditioning and Refrigeration Institute (ARI) Publications:
410 Forced-Circulation Air-Cooling and Air-Heating Coils
430 Central-Station Air-Handling Units
440 Room Fan-Coil Air Conditioners
445 Room Air-Induction Units
880 Air Terminals
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1.2.4 Acoustical Society of America (ASA) Publication:
13 Determination of Sound Levels of Noise Sources in a Special Reverberation Test Room
1.2.5 American Society of Heating, Refrigerating, and Air Conditioning Engineers, Inc. (ASHRAE) Publications:
68 Testing In-Duct Sound Power Measurement Procedure for Fans
71 Rating Unit Ventilators
1.2.6 American Society for Testing and Materials (ASTM) Publications:
A123 Zinc (Hot-Dip Galvanized) Coatings on Iron Steel Products
B117 Salt Spray (Fog) Testing
D1654 Evaluation of Painted or Coated Specimens Subjected to Corrosive Environments
1.2.7 Code of Federal Regulations (CFR) Publication:
29-1910 OSHA Safety and Health Standards
1.2.8 National Electrical Manufacturers Association (NEMA) Publications:
ICS2 Industrial Control Devices, Controllers and Assemblies
ICS6 Enclosures for Industrial Controls and Systems
MG1 Motors and Generators
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1.2.9 National Fire Protection Association (NFPA) Publications:
70 National Electrical Code
90A Installation of Air Conditioning and Ventilating Systems
1.2.10 Underwriters Laboratories, Inc. (UL) Publications:
507 Electric Fans
705 Power Ventilators
883 Fan-Coil Units and Room Fan-Heater Units
1096 Electric Central Air Heating Equipment
1.2.11 Uniform Fire Prevention and Building Code of New York State Publications:
2015 International Mechanical Code
2015 International Energy Conservation Code
2016 Energy Code Supplement
2017 Uniform Code Supplement
1.3 GENERAL REQUIREMENTS: Section 15011, "Mechanical General Requirements" and 15190, “Mechanical Identification” applies to this Section with the additions and modifications specified herein.
1.4 SUBMITTALS:
1.4.1 Manufacturer's Catalog Data:
Manufacturer's Data: Include sound rating data and sound power level for all octave-band center frequencies or loudness level.
a. Fans
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b. Gas-Fired Unit Heaters c. Electric Unit Heaters d. Air Circulating Fans e. Dehumidifier
1.4.2 Test Reports:
Corrosion Test Reports:
Field Test Reports: Include certification by the equipment manufacturer's representative.
1.4.3 Certificates of Compliance:
Certificates of Conformance:
a. Fans b. Gas-Fired Unit Heaters c. Electric Unit Heaters d. Dehumidifier
1.4.4 Operation and Maintenance Manuals:
a. Fans b. Gas-Fired Unit Heaters c. Electric Unit Heaters d. Dehumidifier
1.5 TESTING FOR CORROSION PROTECTION: Comply with ASTM A123, or protect the equipment with a corrosion-inhibiting coating or paint system that has proved capable of satisfactorily withstanding corrosion in accordance with ASTM B117. Test 125 hours for equipment installed indoors and 500 hours for equipment installed outdoors or subjected to a marine atmosphere. Each specimen shall have a standard scratch as defined in ASTM D1654.
1.5.1 Corrosion Criteria: Upon completion of exposure, coating or paint shall show no indication of deterioration, loss of adhesion, or any indication of rust or corrosion extending further than 1/8 inch on either side of original scratch.
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1.5.2 Thickness of Coating: Thickness of coating or paint system on the actual equipment shall be identical to that on the test specimens with respect to materials, conditions of application, and dry film thickness.
1.5.2.1 Mild Steel and Factory Primed Surfaces:
a. Synthetic Resin Primer: 36 percent plus or minus 6 percent solids content by volume; 1 coat, 3 mils minimum dry film thickness.
b. Vinyl Copolymer: 23 percent plus or minus 4 percent solids content by volume; 2 coats, 1-1/2 mils minimum dry film thickness per coat.
1.5.2.2 Nonferrous Heat Exchanger Fin Coil Surfaces: Vinyl copolymer, 4 coats, 1-1/2 mils minimum dry film thickness per coat.
1.5.2.3 Galvanized Surfaces:
a. Polyamide Epoxy Primer: 48 percent plus or minus 2 percent solids content by volume; 1 coat, 2 mils minimum dry film thickness.
b. Vinyl Copolymer: 23 percent plus or minus 4 percent solids content by volume; 2 coats, 1-1/2 mils minimum dry film thickness per coat.
1.5.2.4 Aluminum Surfaces Other than Fin Coil Surfaces:
a. Polyamide Epoxy Primer: 48 percent plus or minus 2 percent solid contact by volume; 1 coat, 2 mils minimum dry film thickness.
b. Vinyl Copolymer: 23 percent plus or minus 4 percent solids content by volume; 2 coats, 1-1/2 mils minimum dry film thickness per coat.
1.6 SAFETY: Comply with OSHA 29 CFR 1910.
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PART 2 - PRODUCTS
2.1 FANS: Sound rating per AMCA 300; statically and dynamically balanced, with air capacities, brake horsepowers, fan types, fan arrangement, sound power levels or loudness level, and static pressure, as indicated. Fan bearing life shall have a minimum average life of 200,000 hours at design operating conditions. Provide guard (bird) screens for outdoor inlets and outlets. Have thermal overload protection in the operating disconnect switches within the building. Construct housings and fan wheels of aluminum or steel, except as specified otherwise. Provide non-sparking construction where indicated.
2.1.1 Propeller Fans: AMCA 210 with AMCA seal, direct drive motors, and statically and dynamically balanced in accordance with AMCA 204. Unit construction shall be cast aluminum tapered airfoil blades and hubs, galvanized steel drive frame assemblies, panels, and wall collar. Fan arrangement shall be either exhaust or supply as indicated on contract drawings. Supply fan arrangement shall include a weatherhood. Motor shall be permanently lubricated heavy ball bearing type, and open drip proof or explosion proof as indicated. Dampers shall be motorized, 120V, and explosion proof where indicated. Manufacture shall be as by Greenheck Model AER, or approved equal.
2.1.2 Power Wall Ventilators: UL 705 with UL label and AMCA 210 with AMCA seal, centrifugal fans in housings of heavy gauge aluminum with curb cap, windband and motor compartment housing with vibration isolators. Equip motors with unfused safety disconnect switches in NEMA 3R enclosure. Provide unit with birdscreen and 120V motorized damper. Manufacture shall be as by Greenheck Model CUE, or approved equal.
2.1.3 In-Line Tubular Axial Fans: UL 705 with UL label and AMCA 210 with AMCA seal, welded tubular steel casings, heavy-duty cast aluminum axial airfoil propeller blades and wheel, stationary discharge conversion vanes, belt guards, and adjustable motor-mounts. Provide flanged connections between fan casings and ductwork. Air shall enter and leave fans axially. Enclose and isolate fan bearings and drive shafts from air stream. Motor shall be explosion mounted out of air stream. Provide vertical base mounted fan supports and vibration isolators. Manufacture shall be as by Greenheck Model TBI-CA, or approved equal.
2.1.4 In-Line Ceiling Mounted Fans: UL 507 with AMCA seal, heavy gauge galvanized steel casing, centrifugal forward-curved type fan, 0.5 inches of interior acoustical insulation, round outlet with aluminum backdraft damper, and high impact polystyrene grille. Motor shall be permanently lubricated, direct drive, open drip-proof type mounted on vibration isolators with thermal overload protection. Provide unit with NEMA 1 rated disconnect switch, speed
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controller and 6-inch diameter wall mounted hooded wall cap (Greenheck Model WC or approved equal). Manufacture shall be as by Greenheck Model SP-AF, or approved equal.
2.1.5 Air-Circulating Fans: UL 507 and UL listed, propeller ceiling type, with size and electrical characteristics as indicated. Provide 120 volt, solid state, wall-mounted, adjustable speed controller to operate up to six (6) ceiling fans together. Speed controller shall provide adjustable speed operation at any point between minimum and maximum fan speeds. Manufacture shall be as by Leading Edge, or approved equal.
2.2 GAS-FIRED UNIT HEATERS: High efficiency, separated combustion, power vented gas-fired unit heaters suitable for use with propane. Units shall be equipped with multi-cell, 4 pass serpentine style steel heat exchanger, with prefabricated 409 stainless steel tubes, and a single, one piece burner assembly with single orifice and venture tube, and built-in disconnect switch. Cabinet shall be low profile with G30 galvanized steel and powder coat finish, roll- formed horizontal louvers spring held and adjustable, safety fan guard, full opening gasketed access panel and safety interlock switch, and designed for ceiling suspension. Controls shall include single-stage gas valve, direct-spark multi-try ignition with electronic flame supervision and times lockout integrally controlled, diagnostic lights, DIP switches, and safety limit switch. Unit shall be supplied with a factory supplied concentric adapter assembly for single wall penetration to the horizontal air inlet and vent terminal. The combustion air/venting system shall include a vibration isolated power venter motor and wheel assembly, and combustion air pressure switch. Unit shall be provided with a gas conversion kit. Manufacture shall be as by Reznor Model UDAS, or approved equal.
2.2.1 Gas-Fired Unit Heater Vent and Combustion Air: Vent shall be double-wall Type B gas vent pipe. Combustion air pipe shall be sealed, single-walled galvanized pipe with slip-fit pipe connections using sheet metal screws or rivets and sealed with aluminum tape or silicone sealant. Furnish and install factory supplied horizontal concentric vent adapter assembly approved for use with the unit heater.
2.3 ELECTRIC UNIT HEATERS (UH-3): UL listed, forced air electric unit heater with capacities as indicated, constructed of 20-gauge die-formed steel housing, stainless steel adjustable louvers, and aluminum-finned copper clad steel sheath heating element with automatic reset linear thermal cut-out, with temperature range of 40 degrees F and 90 degrees F. Provide power disconnect switch and remote wall-mounted thermostat. Manufacture shall be as by Qmark Model MUH, or approved equal.
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2.4 ELECTRIC UNIT HEATER (UH-1): UL listed, fan-forced type, with capacities as indicated, and approved for Class 1, Division 2 hazardous location. Heat exchanger shall be liquid-to-air design, steel tube core with integral aluminum fins, and propylene glycol heat transfer fluid for freeze protection to -49 degrees F. Unit construction shall be 14-gauge steel with polyester powder coating, adjustable outlet lovers and industrial grade electric heating element. Fan motor shall have permanently lubricated ball bearings and built-in thermal overload protection. Provide unit with adjustable built-in thermostat and disconnect switch. Manufacture shall be as by Qmark Model GUX, or approved equal.
2.5 ELECTRIC UNIT HEATER (UH-2): UL listed, forced air electric cabinet unit heater with capacities as indicated, constructed of heavy gauge steel, phosphatized with powder coat finish, semi-recessed galvanized steel backbox, heating element of 80/20 nickel-chromium resistance wire enclosed in steel sheath and copper brazed plate fins. Fan will be four-bladed aluminum with bi-metallic snap-action type control. Fan motor shall be impedance protected, permanently lubricated and with totally enclosed rotor and manual-reset thermal cutout. Thermostat shall be single pole type integral to unit. Manufacture shall be as by Qmark Model CWH, or approved equal.
2.6 DEHUMIDIFIER: Unit shall be a reheat type with scroll compressor with R407c refrigerant, evaporation and hot gas reheat rifled tube lanced fin coils with aluminum extruded fins, stainless steel drain pan, aluminum cleanable filters, adjustable defrost timer, and standard efficiency blower and blower motor. Cabinet is constructed of 18-gauge galvanneal steel with polyester powder coat finish, removable side panels, and closed cell foam insulation. Provide with unit-mounted disconnect, wall-mounted humidistat and floor mounting kit. Manufacture shall be as by Desert Aire LW Series, or approved equal.
PART 3 - EXECUTION
3.1 INSTALLATION: Install air distribution equipment as indicated and in accordance with the manufacturer's instructions. Provide clearance for inspection, repair, replacement, and service. Electrical work shall conform with NFPA 70 and Division 16, "Electrical". Provide overload protection in the operating disconnect switches and magnetic starters.
3.2 FIELD INSPECTION AND TESTS: Schedule and administer the specified tests. Provide personnel, instruments, and equipment for such tests. Correct defects and repeat the respective inspection and tests. Give the Engineer ample notice of the dates and times scheduled for tests and trial operations. Conduct inspection and testing in the presence of the Engineer.
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3.2.1 Field Inspection: Prior to initial operation, inspect equipment installation for conformance with drawings and specifications.
3.2.2 Field Tests:
3.2.2.1 Preliminary Tests: For each item of air handling and distribution equipment and its components, perform an operational test for a minimum period of 2 hours.
3.2.2.2 Testing and Balancing: After preliminary tests, test, adjust, and balance the air handling and distribution equipment in accordance with Section 15895, "Ductwork and Ductwork Accessories".
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - AIR HANDLING AND DISTRIBUTION EQUIPMENT:
4.1.1 Measurement for Air Handling and Distribution Equipment shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - AIR HANDLING AND DISTRIBUTION EQUIPMENT:
4.2.1 For Air Handling and Distribution Equipment, not included in other unit or lump sum price items, payment for Air Handling and Distribution Equipment will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 15850-9 394.107.001 SECTION 15895
DUCTWORK AND DUCTWORK ACCESSORIES
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Ductwork and Ductwork Accessories, as shown on the Plans, as specified and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 Air Diffusion Council (ADC) Publications:
1062-R4 Certification, Rating and Test Manual
AD Measurement of Room-to-Room Sound Transmission Through Plenum Air Systems
1.2.2 American Gas Association (AGA) Publications:
Z21.12 Draft Hoods
Z83.9 Gas-Fired Duct Furnaces
1.2.3 American National Standards Institute, Inc. (ANSI) Publication:
S1.4 Sound Level Meters
1.2.4 Air Movement and Control Association, Inc. (AMCA) Publication:
500 Test Methods for Louvers, Dampers and Shutters
1.2.5 Air-Conditioning and Refrigeration Institute (ARI) Publications:
410 Forced-Circulation Air-Cooling and Air-Heating Coils
610 Central System Humidifiers
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1.2.6 American Society of Heating, Refrigerating, and Air Conditioning Engineers, Inc. (ASHRAE) Publication:
52 Air-Cleaning Devices Used in General Ventilation for Removing Particulate Matter
1.2.7 American Society for Testing and Materials (ASTM) Publications:
A123 Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products
A167 Stainless and Heat-Resisting Chromium - Nickel Steel Plate, Sheet, and Strip
A527 Steel Sheet, Zinc-Coated (Galvanized) by the Hot-Dip Process Lock-Forming Quality
B117 Salt Spray (Fog) Testing
B127 Nickel-Copper Alloy (UNS N04400) Plate, Sheet, and Strip
B152 Copper Sheet, Strip, Plate, and Rolled Bar
C423 Sound Absorption and Sound Absorption Coefficients by the Reverberation Room Method
C553 Mineral Fiber Blanket and Felt Insulation (Industrial Type)
D822 Operating Light- and Water-Exposure Apparatus (Carbon-Arc Type) for Testing Paint, Varnish, Lacquer, and Related Products
D1654 Evaluation of Painted or Coated Specimens Subjected to Corrosive Environments
E90 Laboratory Measurement of Airborne Sound Transmission Loss of Building Partitions
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E96 Water Vapor Transmission of Materials
E437 Industrial Wire Cloth and Screens (Square Opening Series)
1.2.8 Federal Specifications (FS):
F-F-320 Filter, Electronic Air Cleaning Ionizing Plate Type
HH-I-545 Insulation, Thermal and Acoustical (Mineral Fiber, Duct Lining Material)
HH-I-1030 Insulation, Thermal (Mineral Fiber, for Pneumatic or Poured Application)
1.2.9 Military Specifications (MIL):
C-13724 Charcoal, Activated, Impregnated, ASC
D-16886 Dehumidifier, Dry Desiccant Type, Automatic, Continuous Duty
D-28594 Dehumidifier, Rotary, Dry-Desiccant Type, Automatic, Continuous Duty
F-29177 Filter, Air Extended Area, Initial Installation
A-52174 Aluminum Alloy Duct Sheet
1.2.10 National Fire Protection Association (NFPA) Publication:
90A Installation of Air Conditioning and Ventilating Systems
1.2.11 Sheet Metal and Air Conditioning Contractors' National Association, Inc. (SMACNA) Publications:
HVACTAB HVAC Systems - Testing, Adjusting and Balancing (HVACTAB)
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FGDCS Fibrous Glass Duct Construction Standards (FGDCS)
HVACDCS HVAC Duct Construction Standards - Metal and Flexible (HVACDCS)
HVACALTM HVAC Air Duct Leakage Test Manual(HVACALTM)
1.2.12 Underwriters Laboratories, Inc. (UL) Publications:
181 Factory-Made Air Duct Connectors
474 Dehumidifiers
555 Fire Dampers and Ceiling Dampers
555S Leakage Rated Dampers for Use in Smoke Control Systems
586 High Efficiency, Particulate, Air Filter Units
867 Electrostatic Air Cleaners
900 Test Performance of Air Filter Units
998 Humidifiers
1096 Electric Central Air-Heating Equipment
1.3 GENERAL REQUIREMENTS: Section 15011, "Mechanical General Requirements", applies to this Section with the additions and modifications specified herein.
1.4 SUBMITTALS:
1.4.1 Manufacturer's Catalog Data:
a. Dampers b. Flexible ducts and connectors c Dehumidifiers d. Louvers
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DUCTWORK AND DUCTWORK ACCESSORIES
1.4.2 Test Reports:
a. Automatic dampers
1.4.2.1 Automatic Dampers: Submit certification of damper leakage testing and conformance with AMCA 500 and specified maximum leakage or pressure drop requirements.
1.4.3 Certificates of Compliance:
a. Automatic dampers
1.4.4 Field Test Reports:
a. Testing and balancing of air systems
1.5 QUALITY ASSURANCE: SMACNA Duct Construction Manuals: The SMACNA recommendations shall be considered as mandatory requirements. Substitute the word "shall" for the word "should" in these manuals. No negative pressure construction for 4-inch, 6-inch, or 10-inch water gauge is provided herein.
1.6 PRESSURE-VELOCITY CLASSIFICATION: SMACNA HVACDCS, Section 1, and as indicated.
PART 2 - PRODUCTS
2.1 BASIC MATERIALS:
2.1.1 Galvanized Steel Sheets: ASTM A527; coating designation G90.
2.2 DUCTS OF PRESSURE CLASSES 3-INCH OR LESS WATER GAUGE: Construction, metal gauge, hangars and supports, and reinforcements shall conform with SMACNA HVACDCS. Ductwork shall be airtight and shall not vibrate or pulsate when system is in operation. Air leakage shall be less than 5 percent of the system capacity. Construct ductwork of galvanized steel.
2.2.1 Curved Elbows: Make a center line radius not less than 1-1/2 times the width or diameter of the duct.
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2.2.2 Joints: Make airtight. No dust marks from air leaks shall show at duct joints or connections to grilles, registers, and diffusers.
2.2.3 Laps: Make laps at joints in the direction of airflow. Space button punch or bolt connection in standing seams at fixed centers not greater than 6 inches. Longitudinal locks or seams, known as "Button Punch Snap-Lock" may be used in lieu of Pittsburg Lock.
2.2.4 Fittings: Elbows, vaned elbows, take-offs, branch connections, transitions, splitters, volume dampers, fire dampers, flexible connections, and access door shall conform with SMACNA HVACDCS, Section 2. Factory fabricate test holes to be airtight and noncorrosive with screw cap and gasket.
2.3 DUCT SLEEVES AND PREPARED OPENINGS:
2.3.1 Duct Sleeves and Closure Collars: Fabricate from minimum 20-gauge galvanized steel. Where sleeves are installed in bearing walls, provide structural steel sleeves as indicated.
2.3.2 Prepared Openings: Provide one-inch clearance between the duct and the sleeve.
2.4 DAMPERS AND LOUVERS: Construct dampers and louvers with two gauges heavier than ducts in which installed. Except as modified herein, the construction shall be of aluminum or galvanized steel with interlocking edges and maximum 10-inch blade width. Conform with SMACNA HVACDCS.
2.4.1 Manual Volume Dampers: Balancing, factory-fabricated type. Equip dampers with accessible mechanism such as quadrant operators or 3/16-inch rods brought through the side of ducts with locking setscrew and bushing. Where quadrant operators are used, they shall be chrome-plated or enamel painted with all exposed edges rounded.
2.4.2 Louvers: Combination type, performance based on testing in accordance with AMCA Standard 500. Fold or bead the edges of louver blades to exclude driving rain. Louver frames shall be 6-inch depth of extruded aluminum, adjustable combination louver/damper with drainable blades, extruded vinyl blade and jamb seals, side linkage out of airstream. Provide aluminum bird (insect) screen constructed of the same type metal as the louvers. Combination louver/damper shall be rated for operation in a Class 1, Division 2 hazardous location where indicated. Provide combination louver/damper with electrical actuator, 120V, outside of louver where ducted, with on-off operation, spring return, and rated to meet torque requirements of the combination louver damper provided. Actuators shall be provided with built-in mechanical
4.19 15895-6 394.107.001 SECTION 15895
DUCTWORK AND DUCTWORK ACCESSORIES
stops, position indicator, and auxiliary switches where operation is interlocked with other equipment. Where combination louver/dampers are serving the generator or generator room location, the actuator shall be spring to open and power to close. Actuators shall be rated for operation in a Class 1, Division 2 hazardous location and in explosion proof enclosures where indicated. Manufacture shall be as by Greenheck, or approved equal.
2.5 AIR HANDLING AND DISTRIBUTION EQUIPMENT: Section 15850, "Air-Handling and Distribution Equipment".
PART 3 - EXECUTION
3.1 INSTALLATION: Installation shall conform to NFPA 90A, SMACNA HVACDCS. Provide mounting and supporting of ductwork and accessories including, but not limited to, structural supports, hangers, vibration isolators, stands, clamps and brackets, access doors, and dampers. Use electrical isolation between dissimilar metals. Electrical isolation may be fluorinated elastomers or sponge-rubber gaskets. Install ductwork accessories as indicated in accordance with the manufacturer's printed instruction. Allow clearance for inspection, repair, replacement, and service.
3.1.1 Ductwork: When air distribution systems are operated, there shall be no chatter, vibration, or dust marks. After ducts are thermally or acoustically insulated, ensure air flow area equal to duct cross section dimensions indicated.
3.1.1.1 Field Changes to Ductwork: Those required to suit the sizes of factory-fabricated equipment actually furnished, shall be designed to minimize expansion and contraction. Use gradual transitions in field changes as well as modifications to connecting ducts.
3.1.1.2 Dampers: When installed on ducts to be thermally insulated, equip each damper operator with stand-off mounting brackets, bases, or adapters to provide clearance between the duct and operator not less than the thickness of insulation. Stand-off mounting items shall be integral with the operator or standard accessory of damper manufacturer.
3.1.1.3 Duct Sleeves and Prepared Openings: Install for duct mains, duct branches, and ducts passing through roofs and ceilings. The Contractor shall be responsible for the proper size and location of sleeves and prepared openings.
a. Duct Sleeves: Allow one inch clearance between duct and sleeve or one inch
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DUCTWORK AND DUCTWORK ACCESSORIES
clearance between insulation and sleeve for insulated ducts, except at grilles, registers, and diffusers.
b. Prepared Openings: Allow one inch clearance between duct and opening or one inch clearance between insulation and opening for insulated ducts, except at grilles, registers, and diffusers.
c. Closure Collars: Provide not less than 4 inches wide on each side of walls or floors where sleeves or prepared openings are installed. Fit collars snugly around ducts and insulation. Grind smooth edges of collar to preclude tearing or puncturing insulation covering or vapor barrier. Use nails with maximum 6-inch centers on collars.
3.1.2 Duct Hangers and Supports: SMACNA HVACDCS, Section 4. Anchor risers in the center of the vertical run to allow ends of riser free vertical movements. Attach supports only to structural framing members and concrete slabs. Do not anchor supports to metal decking unless a means is provided and approved for preventing the anchors from puncturing the metal decking. Where supports are required between structural framing member, provide suitable intermediate metal framing.
3.1.2.1 Flexible Connectors: Provide flexible connectors between fans and ducts or casings and where ducts are of dissimilar metals. For round ducts, securely fasten flexible connectors by zinc-coated steel clinch-type draw bands. For rectangular ducts, lock flexible connectors to metal collars.
3.1.3 Inspection Plates and Test Holes: Provide, where required, in ductwork or casings for all balance measurements. Test holes shall be factory fabricated, airtight, and noncorrosive with screw cap and gasket. Extend cap through insulation.
3.1.4 Flashings: Provide waterproof flashings where ducts pass through exterior walls and roofs.
3.1.5 Cleaning of Ducts: Remove all debris and dirt from ducts and wipe clean. Before installing air outlets, use air handler to blow dry air through entire system at maximum attainable velocity. Provide temporary air filters for this operation.
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DUCTWORK AND DUCTWORK ACCESSORIES
3.2 FIELD TESTS AND INSPECTIONS: The Contractor is responsible for the administration and direction of tests. Furnish instruments, equipment, connecting devices, and personnel for the tests. Correct all defects in the work. Repeat tests until the work is in compliance.
3.2.1 Performance Testing and Balancing:
3.2.1.1 Balancing and Testing of Air Systems: Comply with SMACNA HVACTAB to achieve and confirm compliance with drawings and specifications, prepare complete report of final test results and submit in quadruplicate.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - DUCTWORK AND DUCTWORK ACCESSORIES:
4.1.1 Measurement for Ductwork and Ductwork Accessories shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - DUCTWORK AND DUCTWORK ACCESSORIES:
4.2.1 For Ductwork and Ductwork Accessories, not included in other unit or lump sum price items, payment for Ductwork and Ductwork Accessories will be made at the applicable price stated in the Bid.
END OF SECTION
4.19 15895-9 394.107.001 SECTION 16011
ELECTRICAL GENERAL REQUIREMENTS
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Electrical General Requirements, as shown on the Plans, as specified and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 Federal Specification (Fed. Spec.):
L-P-387A Plastic Sheet, Laminated, Thermosetting (for Design Plates)
1.2.2 American National Standards Institute (ANSI) Publications:
C37.20 Switchgear Assemblies, Including Metal-Enclosed Bus
Z35.1 Accident Prevention Signs
1.2.3 Institute of Electrical and Electronics Engineers (IEEE) Publication:
100 Standard Dictionary of Electrical and Electronics Terms
1.2.4 National Electrical Manufacturers Association (NEMA) Publication:
ICS 6 Enclosures for Industrial Controls and Systems
1.2.5 National Fire Protection Association (NFPA) Publications:
70B Electrical Equipment Maintenance
70 National Electrical Code
4.19 16011-1 394.107.001 SECTION 16011
ELECTRICAL GENERAL REQUIREMENTS
1.3 APPLICATION: This Section applies to all sections of Division 16, "Electrical", of this project except as specified otherwise in each individual section.
1.4 DEFINITION OF ELECTRICAL TERMS: Unless otherwise specified or indicated, electrical terms used in these Specifications, and on the drawings, shall be as defined in IEEE Standard No. 100.
1.5 ELECTRICAL UTILITY COORDINATION & ELECTRICAL SYSTEM VERIFICATION:
1.5.1 Prior to shop drawing submittals, prior to commencing any demolition and/or prior to commencing any new construction activities, electrical characteristics for all existing and/or proposed electrical systems (including service, premises wiring systems and/or separately derived systems) shall be verified by this Contractor.
1.5.2 Should the Contractor’s verification of any existing or proposed electrical system indicate a discrepancy with the Contract Documents, report them immediately to the Owner and/or Owners designated representative.
1.5.3 Submitting shop drawings and/or commencing any work under this Contract prior to all electrical systems verification/confirmation as required above signifies that Contractor accepts all existing and proposed electrical system characteristics and conditions.
1.6 SUBMITTALS: Obtain approval before procurement, fabrication, or delivery of items to the job site. Partial submittals will not be acceptable and will be returned without review. Submittals shall include the manufacturer's name, trade name, place of manufacture, catalog model or number, nameplate data, size, layout dimensions, capacity, project specification and paragraph reference, applicable Federal, Military, industry, and technical society publication references, and other information necessary to establish contract compliance of each item to be furnished. Furnish a minimum of six (6) copies of shop drawings for each major device specified or electronic shop drawings as specified herein. All hard copy shop drawings shall be a minimum of 8.5 inches by 11 inches in size.
1.6.1 Shop Drawings: In addition to the requirements specified elsewhere, shop drawings shall meet the following requirements. Drawings shall include complete ratings information, wiring diagrams, and installation details of equipment indicating proposed location, layout and arrangement, control panels, accessories, piping, ductwork, and other items that must be shown to assure a coordinated installation. Wiring diagrams shall identify circuit terminals and indicate
4.19 16011-2 394.107.001 SECTION 16011
ELECTRICAL GENERAL REQUIREMENTS
the internal wiring for each item of equipment and the interconnection between each item of equipment. Drawings shall indicate adequate clearance for operation, maintenance, and replacement of operating equipment devices. If equipment is disapproved, revise drawings to show acceptable equipment and resubmit.
1.6.2 Manufacturer's Data: Submittals for each manufactured item shall be current manufacturer's descriptive literature of cataloged products, equipment drawings, diagrams, performance and characteristic curves, and catalog cuts.
1.6.3 Publication Compliance: Where equipment or materials are specified to conform to industry and technical society publications of organizations such as American National Standards Institute (ANSI), American Society for Testing and Materials (ASTM), and Underwriters' Laboratories Inc. (UL), submit proof of such compliance. The label or listing by the specified organization will be acceptable evidence of compliance. In each of the publications referred to herein, consider the advisory provisions to be mandatory, as though the word "shall" had been substituted for "should" wherever it appears. In lieu of the label or listing, submit a certificate from an approved independent testing organization, adequately equipped and competent to perform such services, stating that the item has been tested in accordance with the specified organization's test methods and that the item conforms to the specified organization's publication.
1.6.4 Submittals Required: Supply shop drawing submittal information as otherwise noted in each individual section.
1.6.5 Electronic Shop Drawings: If allowed by other sections of these Contract Documents, electronic submittals shall be submitted to Engineer in accordance with procedures outlined in these Contract Drawings, as established at a preconstruction meeting and/or per Engineer’s written instructions.
1.6.5.1 Electronic shop drawings shall be submitted in an PDF file format or per Engineer’s instructions. Each shop drawing shall be a single electronic file with correct orientation of all sheets contained within.
1.6.5.2 Electronic shop drawings shall be scaled to print at 8.5 inches by 11 inches (for general information, manufacturer’s product data, etc.) and as required for drawings (layout drawings, coordination drawings, schematics, site drawings, electronic copy), except as specified otherwise.
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ELECTRICAL GENERAL REQUIREMENTS
1.6.5.3 Engineer shall make final determination on clarity of electronic shop drawings and will reject electronic shop drawing if resolution is not acceptable.
1.7 OPERATION AND MAINTENANCE MANUAL: Submit as required for systems and equipment indicated in the technical sections. Furnish 3 copies, bound in hardback binders or an approved equivalent. Furnish one complete manual prior to performance of systems or equipment tests, and furnish the remaining manuals prior to contract completion. Inscribe the following identification on the cover: the words "OPERATION AND MAINTENANCE MANUAL", the name and location of the system, equipment, building, name of Contractor, and contract number. Include in the manual the names, addresses, and telephone numbers of each subcontractor installing the system or equipment and the local representatives for the system or equipment. Include a table of contents and assemble the manual to conform to the table of contents, with the tab sheets placed before instructions covering the subject. The instructions shall be legible and easily read, with large sheets of drawings folded in. The manual shall include:
a. Internal and interconnecting wiring and control diagrams with data to explain detailed operation and control of the system or equipment.
b. A control sequence describing startup, operation, and shutdown.
c. Description of the function of each principal item of equipment.
d. Installation and maintenance instructions. e. Safety precautions.
f. Diagrams and illustrations.
g. Testing methods.
h. Performance data.
i. Lubrication schedule including type, grade, temperature range, and frequency.
j. Parts list. The list shall indicate sources of supply, recommended spare parts, and name of servicing organization.
k. Appendix: List qualified permanent servicing organizations for support of the equipment, including addresses and certified qualifications.
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ELECTRICAL GENERAL REQUIREMENTS
1.7.1 Electronic Version: Provide a complete O&M in a single PDF file. PDF file shall be an optical character recognition (OCR) or searchable file.
1.8 SPARE PARTS: Provide spare parts for all equipment installed under this Contract, as indicated in individual specification sections.
1.9 POSTED OPERATING INSTRUCTIONS: Furnish approved operating instructions for systems and equipment indicated in the technical sections for use by operation and maintenance personnel. The operating instructions shall include wiring diagrams, control diagrams, and control sequence for each principal system and equipment. Print or engrave operating instructions and frame under glass or in approved laminated plastic. Post instructions as directed. Attach or post operating instructions adjacent to each principal system and equipment including startup, proper adjustment, operating, lubrication, shutdown, safety precautions, procedure in the event of equipment failure, and other items of instruction as recommended by the manufacturer of each system or equipment. Provide weather-resistant materials or weatherproof enclosures for operating instructions exposed to the weather. Operating instructions shall not fade when exposed to sunlight and shall be secured to prevent easy removal or peeling.
1.10 INSTRUCTION TO OWNER'S PERSONNEL: Where indicated in the technical sections, furnish the services of competent instructors to give full instruction to Owner's personnel in the adjustment, operation, and maintenance of systems and equipment, including pertinent safety requirements as required. Each instructor shall be thoroughly familiar with all parts of the installation and shall be trained in operating theory as well as practical operation and maintenance work. Instruction shall be given during the first regular work week after the equipment or system has been accepted and turned over to the Owner for regular operation. The number of man days (8 hours) of instruction furnished shall be as specified in each individual section.
1.11 LAYOUT OF THE WORK: Coordinate the proper relation of the work to the building structure, existing utilities and to the work of all trades. Visit the premises and become familiar with the dimensions in the field, and advise the Owner's Representative of any discrepancy before performing any work.
1.11.1 Contract Drawings: The Contract Drawings represent the general intent as to layout and equipment arrangements. All locations and dimensions shown shall be field verified and minor alterations made if so required. Where dimensions are not given for the location and arrangement of mechanical systems, locations may be assumed to be approximate, and may be altered if required. Major modifications to the indicated arrangements shall be approved by the
4.19 16011-5 394.107.001 SECTION 16011
ELECTRICAL GENERAL REQUIREMENTS
Owner's Representative prior to the installation of mechanical systems. Schematic diagrams represent the overall system requirements and do not necessarily indicate the physical orientation, location or dimensions of that system.
1.11.3 Record Drawings: The Contractor shall maintain a record of the progress of the work and shall submit three (3) hard copy sets of As-Built Drawings upon completion of the project.
1.12 DELIVERY AND STORAGE: Handle, store, and protect equipment and materials in accordance with the manufacturer's recommendations and with the requirements of NFPA 70B, Appendix I, titled "Equipment Storage and Maintenance During Construction". Replace damaged or defective items with new items.
1.13 SPECIAL CONDITIONS: When performing work within active landfill areas, the Contractor shall be responsible to coordinate with the Owner regarding planned interruptions to electrical services and/or road access. Contractor must maintain in service the existing electrical services at the existing landfill unless otherwise coordinated with the Owner.
1.13.1 Protection of Existing Work: The Contractor shall take all necessary precautions to ensure against damage to existing work to remain in place, or to be reused. The Contractor shall ensure that structural elements are not overloaded and additional structural supports required as a result of any cutting, removal or demolition work performed under any part of this Contract are added. Unless specified otherwise, the Contractor shall submit for review detailed shop drawings applicable to the Contract work for all structural supports, hangers and related devices, structural modifications, temporary rigging and associated rigging plans. Commencement of such work prior to the submission and review of applicable shop drawings shall be at the sole risk of the Contractor.
1.13.2 Upon damage to existing equipment, buildings, and/or structures, the Contractor shall immediately notify the Owner. All damages shall be repaired by the Contractor, or shall be replaced if beyond repair, to match the existing to the Owner's satisfaction.
1.13.3 Protection of Buildings from the Weather: The interior of the buildings and all materials and equipment shall be protected from the weather at all times.
1.13.4 Protection of Personnel: Where the safety of non-contractor personnel is endangered in the area of the work, barricades shall be used. Additional protection shall be provided if required, to preserve the safety of non-contractor personnel in the immediate area of the work.
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ELECTRICAL GENERAL REQUIREMENTS
1.13.5 Contractor shall maintain open road access at all times to the existing landfill. Contractor shall stage construction such that at least one lane of the existing access road is open at all times. Contractor shall coordinate with the Owner a minimum of one week prior to any planned road closings.
1.13.6 Construction in Existing Buildings: Verify with Owner expected routing of new wire and/or conduit within existing equipment or buildings prior to field construction of systems. Coordinate with the Owner a minimum of ten (10) working days prior to any planned disruption of existing working systems.
1.14 CATALOGED PRODUCTS/SERVICE AVAILABILITY: Materials and equipment shall be current products by manufacturers regularly engaged in the production of such products. Products shall have been in satisfactory commercial or industrial use for 2 years prior to bid opening. The 2-year period shall include applications of equipment and materials under similar circumstances and of similar size. The 2-year period shall be satisfactorily completed by a product for sale on the commercial market through advertisements, manufacturers' catalogs, or brochures. Products having less than a 2-year field service record will be acceptable if a certified record of satisfactory field operation for not less than 6000 hours, exclusive of the manufacturers' factory or laboratory tests, is furnished. The equipment items shall be supported by service organizations which are reasonably convenient to the equipment installation in order to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the Contract.
1.15 MANUFACTURER'S RECOMMENDATIONS: Where installation procedures or any part thereof are required to be in accordance with manufacturer's recommendations, furnish printed copies of the recommendations prior to installation. Installation of the item shall not proceed until recommendations are received. Failure to furnish recommendations shall be cause for rejection of the equipment or material. Obtain manufacturer's recommendations from the Owner for equipment and/or material provided by the Owner.
1.16 MOTORS AND MOTOR CONTROLS FOR MECHANICAL EQUIPMENT: The electrical components of mechanical equipment, such as motors, motor starters, control or push button stations, float or pressure switches, solenoid valves, and other devices functioning to control mechanical equipment, and control wiring and conduit for circuits rated 100 volts or less, are specified in the section covering the associated mechanical equipment, rather than in Division 16, unless otherwise shown. The interconnecting power wiring and conduit, control wiring rated 120 volts (nominal) and conduit, and the electrical power circuits shall be furnished and installed under Division 16 in accordance with other sections and/or as shown on the Contract Drawings.
4.19 16011-7 394.107.001 SECTION 16011
ELECTRICAL GENERAL REQUIREMENTS
PART 2 - PRODUCTS
2.1 MATERIALS AND EQUIPMENT: All materials, equipment, and devices shall, as a minimum, meet the requirements of UL where UL standards are established for those items, and the requirements of NFPA 70. All items shall be new unless specified or indicated otherwise.
2.2 NAMEPLATES: Fed. Spec. L-P-387. Provide laminated plastic nameplates for each panelboard, equipment enclosure, relay, switch, and device. Each nameplate inscription shall identify the function and, when applicable, the position. Nameplates shall be melamine plastic, 0.125-inch thick, white with black center core. Surface shall be matte finish. Corners shall be square. Accurately align lettering and engrave into the black core. Minimum size of nameplates shall be 1.0 inch by 2.5 inches. Lettering shall be a minimum of 0.25-inch high normal block style.
2.2.1 For sites with power generation equipment: Provide permanent nameplate at service entrance indicating type and location of on-site generation power source (generator, PV, co-gen, etc.) in accordance with NEC Article 705.
PART 3 - EXECUTION
3.1 NAMEPLATE MOUNTING: Provide number, location, and letter designation of nameplates as indicated. Fasten nameplates to the device with a minimum of two sheet-metal screws or two rivets.
3.1.1 Provide nameplates for all equipment as required by other sections.
3.1.2 Provide nameplates for all owner furnished equipment that is installed by this Contractor.
3.2 PAINTING OF EQUIPMENT:
3.2.1 Factory Applied: Electrical equipment shall have factory-applied painting systems which shall, as a minimum, meet the requirements of NEMA ICS 6 corrosion-resistance test, except equipment specified to meet requirements of ANSI C37.20 shall have a finish as specified in ANSI C37.20.
4.19 16011-8 394.107.001 SECTION 16011
ELECTRICAL GENERAL REQUIREMENTS
3.3 TESTS:
3.3.1 General: Perform and record all tests in the presence of the Owner's authorized representative and/or the Engineer. Furnish all instruments and personnel. Perform preliminary tests and correct all defective material and/or workmanship prior to witness of tests. Perform tests as indicated and as otherwise noted in other Sections of the 16000 Division.
3.3.2 Conduct field tests in the sequence listed below:
3.3.2.1 Insulation Resistance Tests: As required per individual specification sections.
3.3.3 Load Balance Test: Make test by energizing all lighting, motors and other electrical equipment simultaneously for a three-hour period. Alter fuses, circuit breakers, circuit connections, etc., as required for satisfactory performance. Take voltage and amperage readings on each circuit at all panels.
3.3.4 Check the amperage draw, voltage and direction of rotation of each motor in the presence of the equipment contractor and the Owner's representative. Make all necessary changes to obtain proper rotation, motor terminal voltage, motor protection, etc. Revise heater elements as necessary for proper motor protection. Similarly check all other electrically connected equipment.
Make the test at a time during the day or night that is mutually satisfactory to the Owner at least one week prior to substantial completion. Make all arrangements and notify all parties in writing at least seventy-two hours prior to the test.
3.3.5 Equipment Operation Test - Show by demonstration in service that all circuits are in good operating condition. Cycle all control equipment under load at least five times.
3.3.6 Equipment and apparatus factory tests - Manufacturer's normal quality control tests are acceptable, unless specific factory witnessed tests are specified in other sections.
3.3.7 Perform all other field tests as required in individual specification sections.
3.4 CLEANING:
3.4.1 When directed, just prior to final acceptance, clean all equipment including, but not limited to, the following:
4.19 16011-9 394.107.001 SECTION 16011
ELECTRICAL GENERAL REQUIREMENTS
- Lighting fixtures, panelboards, control centers, switchgear, receptacles and switch plates - Remove all tags and labels; leave ready for use - All equipment to be painted, removing all rust, etc., and leave ready for painting - Building, by removing all debris, conduits, wire, insulation, cartons, etc., left as a result of this work.
3.5 THIRD PARTY INSPECTION and MISC SERVICES COORDINATION
3.5.1 Contractor shall provide and pay for inspection of electrical work by the New York Board of Fire Underwriters or other AHJ approved electrical inspection agency.
3.5.2 Contractor shall coordinate with the Owner regarding connections to existing systems and work within existing buildings and equipment.
3.6 WORK WITHIN EXISTING BUILDINGS:
3.6.1 Contractor shall install new feeder breakers in existing panels and shall install new conduit and wire systems within existing buildings. Contractor shall use care in installation of new work and shall protect existing work and finishes in his work area. Contractor shall immediately notify Owner of any damages to existing equipment or finishes and shall restore damaged items to Owner's satisfaction.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - ELECTRICAL GENERAL REQUIREMENTS:
4.1.1 Measurement for Electrical General Requirements shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - ELECTRICAL GENERAL REQUIREMENTS:
4.2.1 For Electrical General Requirements, not included in other unit or lump sum price items, payment for Electrical General Requirements will be made at the applicable price stated in the Bid.
END OF SECTION
4.19 16011-10 394.107.001 SECTION 16115
OUTLET, JUNCTION, AND PULL BOXES
PART 1 GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Outlet, Junction, and Pull Boxes, as shown on the Plans, as specified, and/or directed.
1.2 REFERENCES:
a. NEMA, and UL. (Specifically UL 514A) b. NFPA 70
1.3 SUBMITTALS:
1.3.1 Product Data: Catalog sheets, specifications and installation instructions.
1.3.1.1 For fire rated construction, prove that materials and installation methods proposed for use are in accordance with the listing requirements of the classified construction.
1.4 GENERAL REQUIREMENTS: Section 16011, "Electrical General Requirements", applies to this Section, with the additions and modifications specified herein.
PART 2 - PRODUCTS
2.1 GALVANIZED STEEL OUTLET BOXES:
2.1.1 Standard galvanized steel boxes and device covers by Appleton Electric Co., Cooper/Crouse-Hinds, Hubbell, or approved equal.
2.2 GALVANIZED STEEL JUNCTION AND PULL BOXES:
2.2.1 Code gage, galvanized steel screw cover boxes by Hoffman Enclosures Inc., Hubbell Wiegmann, or approved equal
4.19 16115-1 394.107.001 SECTION 16115
OUTLET, JUNCTION, AND PULL BOXES
2.3 THREADED TYPE BOXES:
2.3.1 Outlet Boxes: For Dry, Damp Locations: Zinc electroplate malleable iron or cast iron alloy boxes by Appleton Electric Co., Cooper/Crouse-Hinds Co., or approved equal with zinc electroplate steel covers to suit application. For classified spaces, provide outlet boxes rated for Class I, Div. 1, group D hazardous areas as manufactured by Crouse-Hinds, Appleton or approved equal.
2.3.2 For Wet Locations: Malleable iron or cast iron alloy boxes with hot dipped galvanized or other specified corrosion resistant finish as produced by Cooper/Crouse-Hinds (hot dipped galvanized or Corro-free epoxy powder coat), or OZ/Gedney Co. (hot dipped galvanized), with stainless steel cover screws, and malleable iron covers gasketed to suit application.
2.3.3 Junction and Pull Boxes:
2.3.3.1 For Dry, Damp Locations: Zinc electroplate cast iron boxes by Appleton Electric Co., Cooper/Crouse-Hinds, or approved equal with zinc electroplate steel or cast iron cover.
2.3.3.2 For Wet Locations: Cast iron boxes by Cooper/Crouse-Hinds’ (hot dipped galvanized or Corro-free epoxy powder coat), or OZ/Gedney Co. (hot dipped galvanized), or approved equal, with stainless steel cover screws and cast iron cover gasketed to suit application.
2.3.3.3 For classified spaces, provide junction and pull boxes rated for Class I, Div. 1, group D hazardous areas as manufactured by Crouse-Hinds, Appleton or approved equal.
2.3.4 Conduit Bodies, Threaded (Provided with a Volume Marking):
2.3.4.1 For Dry, Damp Location: Zinc electroplate malleable iron or cast iron alloy bodies with zinc electroplate steel covers; Appleton Electric Co.’s Unilets, Cooper/Crouse-Hinds’ Condulets, or approved equal.
2.3.4.2 For Wet Locations: Malleable iron or cast iron alloy bodies with hot dipped galvanized or other specified corrosion resistant finish; Cooper/Crouse-Hinds’ Condulets (hot dipped galvanized or Corro-free epoxy power coat), or OZ/Gedney Co.’s Conduit Bodies (hot dipped galvanized) or approved equal, with stainless steel cover screws and malleable iron covers gasketed to suit application.
2.3.4.3 For classified spaces, provide outlet conduit bodies rated for Class I, Div. 1, group D hazardous areas as manufactured by Crouse-Hinds, Appleton, or approved equal.
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OUTLET, JUNCTION, AND PULL BOXES
2.4 SPECIFIC PURPOSE OUTLET BOXES:
2.4.1 As fabricated by manufacturers for mounting their equipment.
PART 3 - EXECUTION
3.1 PREPARATION: Before proceeding with the installation of junction and pull boxes, check the locations with the Director’s Representative and have same approved.
3.2 INSTALLATION:
3.2.1 Mounting Position of Wall Outlets For Wiring Devices: Unless otherwise indicated, install boxes so that the long axis of each wiring device will be vertical.
3.2.2 Height of Wall Outlets: Unless otherwise indicated, locate outlet boxes with their center lines at the following elevations above finished floor:
Switches 4’-0” Single & Duplex Receptacles 1’-6” Special Purpose Receptacles 4’-0”
3.2.3 Supplementary Junction and Pull Boxes: In addition to junction and pull boxes indicated on the drawings and required by NFPA 70, provide supplementary junction and pull boxes as follows:
a. When required to facilitate installation of wiring. b. At every third 90 degree turn in conjunction with raceway sizes over 1 inch. c. At intervals not exceeding 100 feet in conjunction with raceway sizes over 1 inch.
3.3 OUTLET, JUNCTION, AND PULL BOX SCHEDULE:
3.3.1 Boxes For Concealed Conduit System:
3.3.1.1 Non-Fire Rated Construction:
a. Depth: To suit job conditions and comply with NFPA 70 Article 370. b. For Lighting Fixtures: Use galvanized steel outlet boxes designed for the purpose.
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OUTLET, JUNCTION, AND PULL BOXES
i. For Fixtures Weighing 50 lbs. or Less: Box marked “FOR FIXTURE SUPPORT”. ii. For Fixtures More Than 50 lbs: Box listed and marked with the weight of the fixture to be supported (or support fixture independent of the box). c. For Ceiling Suspended Fans: i. For Fans Weighing 35 lbs or Less: Marked “Acceptable for Fan Support.” ii. For Fans Weighing More Than 35 lbs, up to 70 lbs: Marked “Acceptable for Fan Support up to 70 lbs (or support fan independent of the box).” d. For Junction and Pull Boxes: Use galvanized steel boxes with flush covers. e. For Switches, Receptacles, Etc: i. Plaster or Cast-In-Place Concrete Walls: Use 4 inch or 4-11/16 inch galvanized steel boxes with device covers. ii. Walls Other Than Plaster or Cast-In-Place Concrete: Use type of galvanized steel box which will allow wall plate to cover the opening made for the installation of the box.
3.3.2 Boxes For Exposed Conduit System:
3.3.2.1 Dry and Damp Locations: Use zinc electroplate or hot dipped galvanized threaded type malleable iron or cast iron alloy outlet, junction, and pullboxes or conduit bodies provided with a volume marking in conjunction with ferrous raceways unless otherwise specified or indicated on the drawings.
a. Galvanized steel boxes may be used in conjunction with conduit sizes over 1 inch in non-hazardous dry and damp locations. b. Galvanized steel boxes may be used in conjunction with electrical metallic tubing where it is allowed (specified) to be installed exposed as branch circuit conduits at elevations over 10’-0” above finished floor.
3.3.2.2 Wet Locations: Use threaded type malleable iron or cast iron alloy outlet junction, and pullboxes or conduit bodies (provided with a volume marking) with hot dipped galvanized or other specified corrosion resistant coating in conjunction with ferrous raceways unless otherwise specified or indicated on the drawings.
a. Use corrosion resistant boxes in conjunction with plastic coated rigid ferrous metal conduit.
3.3.3 Specific Purpose Outlet Boxes: Use to mount equipment when available and suitable for job conditions. Unless otherwise specified, use threaded type boxes with finish as specified
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OUTLET, JUNCTION, AND PULL BOXES
for exposed conduit system, steel (painted) for surface metal raceway system and galvanized steel for recessed installations.
3.3.4 Stencil cover of pull boxes used on systems over 600 V, in white lettering minimum 1/2 inches high, the words “DANGER HIGH VOLTAGE - KEEP OUT”.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT – OUTLET, JUNCTION, AND PULL BOXES:
4.1.1 Measurement for Outlet, Junction, and Pull Boxes shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT – OUTLET, JUNCTION, AND PULL BOXES:
4.2.1 For Outlet, Junction, and Pull Boxes, not included in other unit or lump sum price items, payment for Outlet, Junction, and Pull Boxes will be made at the applicable price stated in the Bid.
END OF SECTION
4.19 16115-5 394.107.001 SECTION 16123
WIRING/CABLE, 600 VOLTS AND UNDER
PART 1 GENERAL
1.1 DESCRIPTION: Under this Section, the Contractor shall furnish all labor, materials, equipment and accessories for Wiring/Cable, 600 Volts and Under, as shown on the Plans, as specified and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only and shall be the most current version.
1.2.1 National Electrical Manufacturers Association (NECA) Publication:
Standard of Installation
1.2.2 International Electrical Testing Association (NETA) Publication:
ATS Electrical Power Distribution Equipment and Systems
1.2.3 National Fire Protection Association (NFPA) Publication:
70 National Electrical Code
1.2.4 American Society for Testing and Materials (ASTM) Publications:
B1 Hard-Drawn Copper Wire
B8 Concentric-Lay-Stranded Copper Conductors, Hard, Medium-Hard, or Soft
E14 Fire Tests of Through-Penetration Fire Stops
1.2.5 Underwriters Laboratories, Inc. (UL) Publications:
854 Service Entrance Cables
486A Wire Connector and Soldering Lugs for Use with Copper Conductors
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486C Splicing Wiring Connectors
1569 Metal-Clad Cables
1.3 SUBMITTALS:
1.3.1 Product Data: Catalog sheets, specifications and installation instructions.
1.3.2 Specification required test results.
1.4 PRODUCT DELIVERY:
1.4.1 Mark and tag insulated conductors and cables for delivery to the site. Include:
a. Contractor’s name. b. Project title and number. c. Date of manufacture (month & year). d. Manufacturer’s name. e. Environmental suitability information (listed or marked “sunlight resistant” where exposed to direct rays of sun; wet locations listed/marked for use in wet locations; other applications listed/marked suitable for the applications).
PART 2 – PRODUCTS
2.1 INSULATED CONDUCTORS AND CABLES:
2.1.1 Date of Manufacture: No insulated conductor more than one year old when delivered to the site will be acceptable.
2.1.2 Acceptable Companies: American Insulated Wire Corp., BICC General Cable Industries, Inc., Cerro Wire & Cable Co. Inc., Pirelli Cable Corp., Owl Cable Corp., or Southwire Co.
2.1.3 Conductors: Annealed uncoated copper or annealed coated copper in conformance with the applicable standards for the type of insulation to be applied on the conductor. Conductor sizes No. 12 and larger shall be stranded.
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2.1.4 Types:
2.1.4.1 Lighting and Power Wiring:
2.1.4.1.1 Insulation: Unless specified or indicated otherwise or required by NFPA 70, power and lighting wires shall be 600-volt, Type THW, THWN, XHHW, or RHW, except that grounding wire may be Type TW. Where lighting fixtures require 90-degree C conductors, provide only conductors with 90-degree C insulation or better.
2.1.4.1.2 Metal-Clad Cable, NFPA 70 Article 334 Type MC:
a. Interlocked flexible galvanized steel armor sheath, conforming to UL requirements for type MC metal clad cable. b. Insulated copper conductors, suitable for 600 volts, rated 90°C, one of the types listed in NFPA 70 Table 310-13 or of a type identified for use in Type MC cable. c. Internal full size copper ground conductor with green insulation. d. Acceptable Companies: AFC Cable Systems Inc., Coleman Cable Co. e. Connectors for MC cable: AFC Fitting Inc.’s AFC Series, Arlington Industries Inc.’s Saddle grip, or Thomas & Betts Co.’s Tite-Bite with anti-short bushings.
2.1.4.2 Class 1, 2, 3 Wiring: Minimum size for branch circuits shall be No. 12 AWG; for Class 1 remote-control and signal circuits, No. 14 AWG; and for Class 2 low-energy, remote-control and signal circuits, No. 16 AWG.
2.1.4.3 VFD Cables: VFD equipment shall be wired from line side (for standalone VFDs) and load side of VFD (standalone VFDs and MCC VFDs) to motor utilizing VFD rated cable. Cable specifications are as follows:
a. 600V UL 1277 Type TC per 2005 NEC Article 336 b. Copper Conductors c. Class B Stranding per ASTM d. XLPE Insulation XHHW-2 Rated Circuit Conductors (14 AWG and larger) e. 90°C Wet/Dry f. Class I & II; Division 2 Hazardous Locations g. Overall UL 1685 Vertical Tray Flame Test h. IEEE 1202/383 Vertical Tray Flame Test i. Overall Shield
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2.2 CONNECTORS:
2.2.1 General:
2.2.1.1 Connectors specified are part of a system. Furnish connectors and components, and use specific tools and methods as recommended by connector manufacturer to form complete connector system.
2.2.1.2 Connectors shall be UL 486 A listed, or UL 486 B listed for combination dual rated copper/aluminum connectors (marked AL7CU for 75 degrees C rated circuits and AL9CU for 90 degrees C rated circuits).
2.2.2 Splices:
2.2.2.1 Spring Type:
a. Rated 105° C, 600V; Buchanan/Ideal Industries Inc.’s B-Cap, Electrical Products Div./3M’s Scotchlok Type Y, R, G, B, O/B+, R/Y+, or B/G+, or Ideal Industries Inc.’s Wing Nuts or Wire Nuts. b. Rated 150° C, 600V; Ideal Industries Inc.’s High Temperature Wire-Nut Model 73B, 59B.
2.2.2.2 Indent Type with Insulating Jacket: Rated 105° C, 600V; Buchanan/Ideal Industries Inc.’s Crimp Connectors, Ideal Industries Inc.’s Crimp Connectors, Penn-Union Corp.’s Penn- Crimps, or Thomas & Betts Corp.’s STA-KON.
2.2.2.3 Indent Type (Uninsulated): Anderson/Hubbell’s Versa-Crimp, VERSAtile, Blackburn/T&B Corp.’s Color-Coded Compression Connectors, Electrical Products Div./3M’s Scotchlok 10000, 11000 Series, Framatome Connectors/Burndy’s Hydent, Penn-Union Corp.’s BCU, BBCU Series, or Thomas & Betts Corp.’s Compression Connectors.
2.2.2.4 Connector Blocks: NIS Industries Inc.’s Polaris System, or Thomas & Betts Corp.’s Blackburn AMT Series.
2.2.2.5 Resin Splice Kits: Electrical Products Div./3M’s Scotchcast Brand Kit Nos. 82A Series, 82-B1 or 90-B1, or Scotchcast Brand Resin Pressure Splicing Method.
2.2.2.6 Heat Shrinkable Splices: Electrical Products Div./3M’s ITCSN, Raychem Corp.’s Thermofit Type WCS, or Thomas & Betts Corp.’s SHRINK-KON Insulators.
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2.2.2.7 Cold Shrink Splices: Electrical Products Div./3M’s 8420 Series.
2.2.3 Gutter Taps: Anderson/Hubbell’s GP/GT with GTC Series Covers, Blackburn/T&B Corp.’s H-Tap Type CF with Type C Covers, Framatome Connectors/Burndy’s Polytap KPU-AC, H-Crimpit Type YH with CF-FR Series Covers, ILSCO’s GTA Series with GTC Series Covers, Ideal Industries Inc.’s Power-Connect GP, GT Series with GIC covers, NSI Industries Inc.’s Polaris System, OZ/Gedney Co.’s PMX or PT with PMXC, PTC Covers, Penn-Union Corp.’s CDT Series, or Thomas & Betts Corp.’s Color-Keyed H Tap CHT with HTC Covers.
2.2.4 Terminals: Nylon insulated pressure terminal connectors by Amp-Tyco/Electronics, Electrical Products Div./3M, Framatome Connectors/Burndy, Ideal Industries Inc., Panduit Corp., Penn-Union Corp., Thomas & Betts Corp., or Wiremold Co.
2.2.5 Lugs:
2.2.5.1 Single Cable (Compression Type Lugs): Copper, 1 or 2 hole style (to suit conditions), long barrel; Anderson/Hubbell’s VERSAtile VHCL, Blackburn/T&B Corp.’s Color-Coded CTL, LCN, Framatome Connectors/Burndy’s Hylug YA, Electrical Products Div./3M Scotchlok 31036 or 31145 Series, Ideal Industries Inc.’s CCB or CCBL, NSI Industries Inc.’s L, LN Series, Penn- Union Corp.’s BBLU Series, or Thomas & Betts Corp.’s 54930BE or 54850BE Series.
2.2.5.2 Single Cable (Mechanical Type Lugs): Copper, one or 2 hole style (to suit conditions); Blackburn/T&B Corp.’s Color-Keyed Locktite Series, Framatome Connectors/Burndy’s Qiklug Series, NSI Industries Inc.’s Type TL, Penn-Union Corp.’s VI-TITE Terminal Lug Series, or Thomas & Betts Corp.’s Locktite Series.
2.2.5.3 Multiple Cable (Mechanical Type Lugs): Copper, configuration to suit conditions; Framatome Connectors/Burndy’s Qiklug Series, NSI Industries Inc.’s Type TL, Penn-Union Corp.’s VI-TITE Terminal Lug Series, or Thomas & Betts Corp.’s Color-Keyed Locktite Series.
2.3 TAPES:
2.3.1 Insulation Tapes:
2.3.1.1 Plastic Tape: Electrical Products Div./3M’s Scotch Super 33+ or Scotch 88, Plymouth Rubber Co.’s Plymouth/ Bishop Premium 85CW.
2.3.1.2 Rubber Tape: Electrical Products Div./3M’s Scotch 130C, or Plymouth Rubber Co.’s Plymouth/Bishop W963 Plysafe.
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2.3.2 Moisture Sealing Tape: Electrical Products Div./3M’s Scotch 2200 or 2210, or Plymouth Rubber Co.’s Plymouth/Bishop 4000 Plyseal-V.
2.3.3 Electrical Filler Tape: Electrical Products Div./3M’s Scotchfil, or Plymouth Rubber Co.’s Plymouth/Bishop 125 Electrical Filler Tape.
2.3.4 Color Coding Tape: Electrical Products Div./3M’s Scotch 35, or Plymouth Rubber Co.’s Plymouth/Bishop Premium 37 Color Coding.
2.3.5 Arc Proofing Tapes:
2.3.5.1 Arc Proofing Tape: Electrical Products Div./3M’s Scotch 77, Mac Products Inc.’s AP Series, or Plymouth Rubber Co.’s Plymouth/Bishop 53 Plyarc.
2.3.5.2 Glass Cloth Tape: Electrical Products Div./3M’s Scotch 27/Scotch 69, Mac Products Inc.’s TAPGLA 5066,, or Plymouth Rubber Co.’s Plymouth/Bishop 77 Plyglas.
2.3.5.3 Glass-Fiber Cord: Mac Products Inc.’s MAC 0527.
2.4 WIRE-PULLING COMPOUNDS: To suit type of insulation; American Polywater Corp.’s Polywater Series, Electric Products Div./3M’s WL, WLX, or WLW, Greenlee Textron Inc.’s Y-ER-EAS, Cable Cream, Cable Gel, Winter Gel, Ideal Industries Inc.’s Yellow 77, Aqua- Gel II, Agua-Gel CW, or Thomas & Betts Corp.’s Series 15-230 Cable Pulling Lubricants, or Series 15-631 Wire Slick.
2.5 TAGS: Precision engrave letters and numbers with uniform margins, character size minimum 3/16 inch high.
2.5.1 Phenolic: Two color laminated engraver’s stock, 1/16 inch minimum thickness, machine engraved to expose inner core color (white).
2.5.2 Aluminum: Standard aluminum alloy plate stock, minimum .032 inch thick, engraved areas enamel filled or background enameled with natural aluminum engraved characters.
2.6 WIRE MANAGEMENT PRODUCTS: Cable Clamps and Clips, Cable Ties, Spiral Wraps, etc: Catamount/T&B Corp., or Ideal Industries Inc.
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PART 3 - EXECUTION
3.1 INSTALLATION:
3.1.1 Install conductors in raceways after the raceway system is completed. Exceptions: Type TC, MI, or other type specifically indicated on the drawings not to be installed in raceways.
3.1.2 No grease, oil, or lubricant other than wire-pulling compounds specified may be used to facilitate the installation of conductors. Completely and thoroughly swab raceway/wire before installing wire/cable.
3.2 CIRCUITING:
3.2.1 Wiring and cables of different systems shall not be run in same raceway. Power wiring shall not be run in same raceway for remote control/signal wiring.
3.2.2 Class 2, 3 plenum rated cables shall be run without raceway when concealed above accessible ceilings unless otherwise indicated on Contract Drawings. These cables shall be run parallel and perpendicular to building surfaces, and shall be neatly bundled and shall be supported independently from the accessible ceiling. Provide conduit sleeves at wall penetrations.
3.3 COMMON NEUTRAL CONDUCTOR:
3.3.1 A common neutral shall not be used. Provide individual neutral per each circuit.
3.4 COLOR CODING:
3.4.1 Color Coding for 120/208/240 Volt Electric Light and Power Wiring:
3.4.1.1 Color Code:
a. 2 wire circuit - black, white. b. 3 wire circuit - black, red, white. c. 4 wire circuit - black, red, blue, white.
3.4.1.2 White to be used only for an insulated grounded conductor (neutral). If neutral is not required use black and red, or black, red and blue for phase to phase circuits.
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3.4.1.2.1 “White” for Sizes No. 6 AWG or Smaller:
a. Continuous white outer finish, or: b. Three continuous white stripes on other than green insulation along its continuous length.
3.4.1.2.2 “White” for Sizes Larger Than No. 6 AWG:
a. Continuous white outer finish, or: b. Three continuous white stripes on other than green insulation along its continuous length, or: c. Distinctive white markings (color coding tape) encircling the conductor, installed on the conductor at time of its installation. Install white color coding tape at terminations, and at 1’ 0” intervals in gutters, pull boxes, and manholes.
3.4.1.3 Colors (Black, Red, Blue):
3.4.1.3.1 For Branch Circuits: Continuous color outer finish.
3.4.1.3.2 For Feeders:
a. Continuous color outer finish, or: b. Color coding tapes encircling the conductors, installed on the conductors at time of their installation. Install color coding tapes at terminations, and at 1’ 0” intervals in gutter, pullboxes, and manholes.
3.4.2 Color Coding For 277/480 Volt Electric Light and Power Wiring:
3.4.2.1 Color Code:
a. 2 wire circuit – brown, gray. b. 3 wire circuit – brown, yellow, gray. c. 4 wire circuit – brown, orange, yellow, gray.
3.4.2.2 Gray to be used only for an insulated grounded conductor (neutral). If neutral is not required use brown and yellow, or brown, yellow and orange for phase to phase circuits.
a. “Gray” For Sizes No. 6 AWG or Smaller: i. Continuous gray outer finish.
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b. “Gray” For Sizes Larger Than No. 6 AWG: i. Distinctive gray markings (color coding tape) encircling the conductor, installed on the conductor at time of its installation. Install gray color coding tape at terminations, and at 1’ 0” intervals in gutters, pull boxes, and manholes. c. Colors (Brown, Yellow, Orange): d. For Branch Circuits: Continuous color outer finish. e. For Feeders: i. Continuous color outer finish, or: ii. Color coding tapes encircling the conductors, installed on the conductors at the time of their installation. Install color coding tapes at terminations, and at 1’ 0” intervals in gutters, pullboxes, and manholes.
3.4.3 More Than One Nominal Voltage System Within A building: Permanently post the color coding scheme at each branch-circuit panelboard.
3.4.4 Existing Color Coding Scheme: Where an existing color coding scheme is in use, match the existing color coding if it is in accordance with the requirements of NFPA 70.
3.4.5 Color Code For Wiring Other Than Light and Power: In accordance with ICEA/NEMA WC-30 “Color Coding of Wires and Cables”. Other coding methods may be used, as approved.
3.4.6 On 3-phase, 4-wire delta system, high leg shall be orange, as required by NFPA 70.
3.5 IDENTIFICATION:
3.5.1 Identification Tags: Use tags to identify feeders and designated circuits. Install tags so that they are easily read without moving adjacent feeders or requiring removal of arc proofing tapes. Attach tags with non-ferrous wire or brass chain.
3.5.1.1 Interior Feeders: Identify each feeder in pullboxes and gutters. Identify by feeder number and size.
3.5.1.2 Exterior Feeders: Identify each feeder in manholes and in interior pullboxes and gutters. Identify by feeder number and size, and also indicate building number and panel designation from which feeder originates.
3.5.1.3 Street and Grounds Lighting Circuits: Identify each circuit in manholes and lighting standard bases. Identify by circuit number and size, and also indicate building number and panel designation from which circuit originates.
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3.5.2 Identification Plaque: Where a building or structure is supplied by more than one service, or has any combination of feeders, branch circuits, or services passing through it, install a permanent plaque or directory at each service, feeder and branch circuit disconnect location denoting all other services, feeders, or branch circuits supplying that building or structure or passing through that building or structure and the area served by each.
3.6 WIRE MANAGEMENT:
3.6.1 Use wire management products to bundle, route, and support wiring in junction boxes, pullboxes, wireways, gutters, channels, and other locations where wiring is accessible.
3.7 EQUIPMENT GROUNDING CONDUCTOR:
3.7.1 Install Equipment Grounding Conductor:
3.7.1.1 Where specified in other Sections or indicated on the Contract Drawings.
3.7.1.2 In conjunction with circuits recommended by equipment manufacturers to have equipment grounding conductor.
3.7.2 Equipment grounding conductor is not intended as a current carrying conductor under normal operating circumstances.
3.7.3 Color Coding For Equipment Grounding Conductor:
3.7.3.1 Color Code: Green.
3.7.3.2 “Green” For sizes No. 6 AWG or Smaller:
a. Continuous green outer finish, or: b. Continuous green outer finish with one or more yellow stripes, or: c. Bare copper (see exception below).
3.7.3.3 “Green” For Sizes Larger Than No. 6:
a. Stripping the insulation or covering from the entire exposed length (see exception below). b. Marking the exposed insulation or covering with green color coding tapes. b. Identify at each end and at every point where the equipment grounding conductor is accessible.
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3.7.3.4 Exception For use of Bare Copper: Not allowed for use where NFPA 70 specifically requires equipment grounding conductor to be insulated, or where specified in other sections or indicated on the drawings to be insulated.
3.8 SPECIAL GROUNDING CONDUCTORS:
3.8.1 Technical Power System Grounding (Equipment grounding conductor isolated from the premises grounded conductor except at a single grounded termination point): Install an insulated grounding conductor running with the circuit conductors for isolated receptacles or utilization equipment requiring an isolated ground.
3.8.1.1 Color Code: Green.
3.8.1.2 “Green” For Isolated Grounding Conductor:
a. Continuous green outer finish, or: b. Continuous green outer finish with one or more yellow stripes, and: c. Different than the “green” used for the equipment grounding conductor run with the circuit (where required).
3.8.1.3 Install label at every point where the conductor is accessible, identifying it as an “Isolated Grounding Conductor”.
3.9 ARC PROOFING:
3.9.1 Arc proof feeders installed in a common pullbox or manhole as follows:
3.9.1.1 Arc proof new feeders.
3.9.1.2 Arc proof existing feeders that are spliced to new feeders.
3.9.1.3 Arc proof each feeder as a unit (except feeders consisting of multiple sets of conductors).
3.9.1.4 Arc proof feeders consisting of multiple sets of conductors by arc proofing each set of conductors as a unit.
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3.9.1.5 Arc proof feeders with half-lapped layer of 55 mils thick arc proofing tape and random wrapped or laced with glass cloth tape or glass-fiber cord. For arc proofing tape less than 55 mils thick, add layers to equivalent of 55 mils thick arc proofing tape.
3.10 INSULATED CONDUCTOR AND CABLE SCHEDULE - TYPES AND USE:
3.10.1 Electric Light and Power Circuits:
3.10.1.1 FEP, THHN, THW, THW-2, THWN, THWN-2, XHH, XHHW, or XHHW-2: Wiring in dry or damp locations (except where special type insulation is required).
3.10.1.2 THWN, THWN-2, XHHW, XHHW-2, USE, or USE-2: Wiring in wet locations (except where type USE or USE-2 insulated conductors are specifically required, or special type insulation is required).
3.10.1.3 THHN, THWN or THWN-2: Wiring installed in existing raceway systems (except where special type insulation is required).
3.10.1.4 THHN, THW-2, THWN-2, XHHW, or XHHW-2: Wiring for electric discharge lighting circuits (fluorescent, HID), except where fixture listing requires wiring rated higher than 90° C.
3.10.1.5 THWN Marked “Gasoline and Oil Resistant”: Wiring to gasoline and fuel oil pumps.
3.10.1.6 USE, or USE-2: Wiring indicated on the drawings to be direct burial in earth.
3.10.1.7 USE, or USE-2 Marked “Sunlight Resistant”:
a. Service entrance wiring from overhead service to the service equipment. b. Wiring exposed to the weather and unprotected (except where special type insulation is required).
3.10.1.8 MC:
a. Branch circuit wiring in wood framed construction (wood joists and wood stud partitions): i. Install conductors parallel with joists or studs and attach to the side of these timbers by galvanized straps spaced not more than 6 feet apart.
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ii. Install conductors through holes bored in the center of the timbers when running at right angles to joists or studs. iii. Do not attach the conductors to the edge of joists or studs. b. Branch circuit wiring in movable metal partitions and movable gypsum partitions. i. Install conductors in accordance with partition manufacturer’s recommendations. c. Branch circuit wiring in metal stud partitions: i. Install conductors parallel with studs and attach to the side by galvanized straps spaced not more than 6 feet apart. ii. Install conductors through holes bored in the center of the metal member when running at right angles to studs. a) Conductors shall be protected by listed bushings or listed grommets covering all metal edges. iii. Do not attach the conductors to the edge of studs.
3.10.1.9 MI:
a. Wiring for underplaster extensions. b. Wiring in areas where indicated on the Contract Drawings. c. Where MI cable is installed in areas subjecting cable to corrosion, use PVC or HDPE jacketed MI cable (nonmetallic jacketed cable is not suitable for use in ducts, plenums or other spaces used for environmental air).
3.10.2 Emergency Feeder Circuits: Use electrical circuit protective system.
3.10.3 Class 1 Circuits: Use Class 1 wiring specified in Part 2 (except where special type insulation is required).
3.10.4 Class 2 Circuits: Use Class 2 wiring specified in Part 2 (except where special type insulation is required).
3.10.5 Class 3 Circuits: Use Class 3 wiring specified in Part 2 (except where special type insulation is required).
3.11 CONNECTOR SCHEDULE - TYPES AND USE:
3.11.1 Temperature Rating: Use connectors that have a temperature rating, equal to, or greater than the temperature rating of the conductors to which they are connected.
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3.11.2 Splices:
3.11.2.1 Dry Locations:
3.11.2.1.1 For Conductors No. 8 AWG or Smaller: Use spring type pressure connectors, indent type pressure connectors with insulating jackets, or connector blocks (except where special type splices are required).
3.11.2.1.2 For Conductors No. 6 AWG or Larger: Use connector blocks or uninsulated indent type pressure connectors. Fill indentions in uninsulated connectors with electrical filler tape and apply insulation tape to insulation equivalent of the conductor, or insulate with heat shrinkable splices or cold shrink splices.
3.11.2.1.3 Gutter Taps in Panelboards: For uninsulated type gutter taps fill indentions with electrical filler tape and apply insulation tape to insulation equivalent of the conductor, or insulate with gutter tap cover.
3.11.2.2 Damp Locations: As specified for dry locations, except apply moisture sealing tape over the entire insulated connection (moisture sealing tape not required if heat shrinkable splices or cold shrink splices are used).
3.11.2.3 Wet Locations: Use uninsulated indent type pressure connectors and insulate with resin splice kits, cold shrink splices or heat shrinkable splices. Exception: Splices aboveground which are totally enclosed and protected in NEMA 3R, 4, 4X enclosures may be spliced as specified for damp locations.
3.11.3 Terminations:
3.11.3.1 For Conductors No. 10 AWG or Smaller: Use terminals for:
a. Connecting wiring to equipment designed for use with terminals.
3.11.3.2 For Conductors No. 8 AWG or Larger: Use compression or mechanical type lugs for:
a. Connecting cables to flat bus bars. b. Connecting cables to equipment designed for use with lugs.
4.19 16123-14 394.107.001 SECTION 16123
WIRING/CABLE, 600 VOLTS AND UNDER
3.11.3.3 For Conductor Sizes Larger Than Terminal Capacity On Equipment: Reduce the larger conductor to the maximum conductor size that terminal can accommodate (reduced section not longer than one foot). Use compression or mechanical type connectors suitable for reducing connection.
3.12 TESTING:
3.12.1 Insulation Resistance Tests: Make tests after all wiring is completed and connected ready for the attachment of fixture and/or equipment. Repeat test when all fixtures and/or equipment are connected ready for use. Make tests with an instrument capable of measuring the resistance involved at a voltage of at least 500 VDC for equipment rated at 100 to 500 VAC, 1500 VDC for equipment rated at 151 to 600 VAC. Apply voltage continuously for one minute prior to taking reading. Measure insulation resistance between each pair of insulated conductor separately and between each insulated conductor and ground. Make tests at each panelboard distribution panel, and switchboard on every circuit with the circuit protective device open but connected. The minimum acceptable measured insulation resistance for wiring completed and ready for connection of fixtures and/or equipment is 50 meg ohms.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT – WIRING/CABLE, 600 VOLTS AND UNDER:
4.1.1 Measurement for Wiring/Cable, 600 Volts and Under shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT – WIRING/CABLE, 600 VOLTS AND UNDER:
4.2.1 For Wiring/Cable, 600 Volts and Under, not included in other unit or lump sum price items, payment for Wiring/Cable, 600 Volts and Under will be made at the applicable price stated in the Bid.
END OF SECTION
4.19 16123-15 394.107.001 SECTION 16126
PRIMARY WIRING - 15KV NOMINAL
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Primary Wiring – 15kV Nominal, as shown on the Plans, as specified, and/or directed. Note this section specifies Primary Wiring - 15kV Nominal for use underground or in conduit only (up riser poles).
1.2 REFERENCES: The publications listed below and their latest revisions form a part of the Specifications to the extent referenced. The publications are referred to in the text by the basic designation only and shall be the most current version.
1.2.1 Insulated Cable Engineers Association (ICEA) Publication:
S-94-649/NEMA WC-74 Ethylene-Propylene Rubber Insulated Wire and Cable for the Transmission and Distribution of Electrical Energy
1.2.2 Association of Edison Illuminating Companies (AEIC) Publication:
CS-8 Ethylene Propylene Rubber Insulated Shielded Power Cables Rated 5 through 69KV
1.2.3 Institute of Electrical and Electronics Engineers (IEEE) Publications:
48 Standard Test Procedures and Requirements for High-Voltage Alternating-Current Cable Terminations
400 Guide for Field testing and Evaluation of the Insulation of Shielded Power Cable Systems Rated 5kV and above
1.2.4 Underwriters Laboratories (UL) Publication:
1072 Medium Voltage Power Cables
4.19 16126-1 394.107.001 SECTION 16126
PRIMARY WIRING - 15KV NOMINAL
1.3 SUBMITTALS:
1.3.1 Submittals Package: Submit the data specified below for preliminary approval all at the same time as a package. After preliminary approval, submit the data and samples specified below for final approval all at the same time as a package.
1.3.2 Submit the following:
a. Complete manufacturer's construction details and specifications for the cables, including physical and electrical characteristics of insulation, shields and jackets. b. Overall dimension and ampacity of cable. c. Catalog sheets, specifications and installation instructions for all products. d. Certification of acceptance from National Grid that insulated cable and sectionalizing cabinet meets their specifications.
1.3.3 Contract Closeout Submittals:
a. Test Report: High voltage (Hipot) after installation test report. b. Certificates: i. Affidavit, signed by the cable manufacturer's Company Field Advisor and notarized, certifying that the cable has been installed in accordance with the manufacturer's recommendations and is operating properly. ii. Affidavit, signed by the splice and termination manufacturer's Company Field Advisor and notarized, certifying that the splices (if required) and terminations were constructed in accordance with the manufacturer's recommendations and are operating properly.
1.4 QUALITY ASSURANCE:
1.4.1 Equipment Qualifications For Products Other Than Those Specified:
1.4.1.1 If products other than those specified are proposed for use furnish the name, address, and telephone numbers of at least 5 comparable installations that can prove the proposed products have performed satisfactorily for 10 years.
1.4.1.2 Provide written certification from the manufacturer that the proposed products are compatible for use with all other equipment proposed for use for this system and meet all contract requirements. Include proof that the installed cables:
a. Have the same rating and construction as the proposed cable.
4.19 16126-2 394.107.001 SECTION 16126
PRIMARY WIRING - 15KV NOMINAL
b. Have the same insulation compound as the proposed cable.
1.4.2 Company Field Advisor: Secure the services of the cable manufacturer's Company Field Advisor for a minimum of 16 working hours for the following:
a. Render advice regarding method of installing cable. b. Inspection of equipment for installing cable. c. Witness representative amount of cable pulling. d. Witness construction of at least one splice and one termination by each cable splicer who will be doing the actual cable splicing. If cable splices are necessary. i. If the splices or terminations are other than the cable manufacturer's, secure the services of the splice and termination manufacturer's Company Field Advisor to concurrently witness construction of the splices and terminations and also certify with an affidavit that the splices and terminations were constructed in accordance with the splice and termination manufacturer's recommendations. e. Witness high voltage after installation test. f. Certify with an affidavit that the aforementioned particulars are satisfactory and the cable is installed in accordance with cable manufacturer's recommendations.
1.4.3 Testing Company: Secure the services of an approved testing company for a high voltage after installation test.
1.4.4 Resume of each cable splicer's experience. Include:
a. Details of type of high voltage splicing and terminations performed. b. Types of cables which were spliced. c. Job locations. d. Number of years performing splices and terminations. e. Certificate of training from the splice/termination manufacturer for heat- shrinkable products, if used. f. Certifications of terminating elbow type connections
1.5 DELIVERY, STORAGE AND HANDLING:
1.5.1 Cable Delivery:
1.5.1.1 No insulated cable over one year old when delivered to the site will be acceptable.
1.5.1.2 Keep ends of cables sealed at all times, except when making splices or terminations. Use soldered seals for lead sheath cables. For other type cables use heat shrinkable plastic end
4.19 16126-3 394.107.001 SECTION 16126
PRIMARY WIRING - 15KV NOMINAL
caps with sealant as produced by Raychem Corp., or Thomas & Betts Corp., or other methods approved by cable manufacturer.
1.5.1.3 Include the following data durably marked on each reel:
a. Facility name and address. b. Contractor's name. c. Project title and number. d. Date of manufacture. e. Cable size and voltage rating. f. Manufacturer's name. g. Linear feet of cable. h. Location where cable is to be installed.
1.5.2 Cable Storage: Store where cable will be at optimum workability temperature recommended by cable manufacturer.
1.6 PRE-CABLE INSTALLATION CERTIFICATION:
1.6.1 Provide certification that existing conduits have been prepped as specified herein (Part 3) for the installation of new MV cable. Provide certification prior to cable installation.
PART 2 - PRODUCTS
2.1 CABLES:
2.1.1 Cable Configuration: Single conductor.
2.1.2 5 kV Cable Construction :
a. 1/C cable, AWG per Contract Drawings. b. Class B compressed stranded copper conductors. c. 133%, 220 mils EPR insulation (discharge resistant). d. Copper Tape Shield: Helically wrapped 5 mil copper tape with 25% overlap. e. Conductor Shield: Semi-conducting cross inked copolymer. f. Jacket: Insulating polyvinyl chloride (PVC), sunlight resistant, -40 Deg C. g. Insulation Shield: Strippable, semi-conducting layer, cross-linked copolymer. h. Temperature Ratings: MV-105°C normal. i. Rated 5 kV.
4.19 16126-4 394.107.001 SECTION 16126
PRIMARY WIRING - 15KV NOMINAL
j. Suitable for use UL wet and dry, in conduits, ducts, troughs, trays and direct burial. k. UL Listed. l. Southwire 5kV “SPEC 46102 1/C CU 5KV NL-EPR 133% TS SUMpull PVC 105” Cable or equal.
2.2 15KV LOAD BREAK ELBOW TERMINATIONS AND EQUIPMENT (AT OUTDOOR PAD MOUNTED TRANSFORMERS):
2.2.1 Materials: All materials required for a complete termination shall be the standard product of one manufacturer, designed specifically for the type of cable and conductor to be terminated.
2.2.2 Ampere Rating: 200 amp continuous, load break
2.2.3 Voltage Rating: Not less than voltage rating of cable.
2.2.4 Manufacturer: Elastimold, Cooper, or approved equal. For each phase conductor that terminates at the transformers, provide a 200A Series load-break elbow kit with:
a. compression lug suitable for specified 5 kV, MV cable b. cable shield adapter c. cable jacket seal d. test point
2.2.5 Transformer bushing wells and bushing well inserts shall be of same manufacture as elbow connectors.
2.2.6 Provide load break protective cap for all un-used transformer primary side bushings.
2.3 ACCESSORIES:
2.3.1 Arc Proofing Tapes:
2.3.1.1 Arc Proofing Tape: Mac Products Inc's AP30-30 or AP, Minnesota Mining & Mfg. Co.'s 3M 77, Plymouth Rubber Co.'s Plymouth Bishop 53 Plyarc, or Quelcor Inc.'s Quelpyre.
2.3.1.2 Glass Cloth Tape: Mac Products Inc.'s TAPGLA 5066, Minnesota Mining & Mfg. Co.'s 3M 69, or Plymouth Rubber Co.'s Plymouth Bishop 77 Plyglas.
2.3.1.3 Glass-Fiber Cord: Mac Products Inc.'s MAC 0527, or Quelcor Inc.'s QTC-250.
4.19 16126-5 394.107.001 SECTION 16126
PRIMARY WIRING - 15KV NOMINAL
2.3.2 Tags: Precision engrave letters and numbers with uniform margins, character size minimum 3/16 inches high.
2.3.2.1 Phenolic: Two color laminated engraver's stock, 1/16 inch minimum thickness, machine engraved to expose inner core color (white).
2.3.2.2 Aluminum: Standard aluminum alloy plate stock, minimum .032 inches thick, engraved areas enamel filled or background enameled with natural aluminum engraved characters.
2.3.3 Heat Shrink Seal: Cable ends to be sealed at all times and resealed when cut to prevent contamination of the cables by moisture and dirt. Provide heat shrink seal designed specifically for the type of cable and conductor to be installed.
PART 3 - EXECUTION
3.1 INSTALLATION:
3.1.1 Cables:
3.1.1.1 Cables to be installed in combination of new and existing conduit/duct bank systems as shown on the Contract Drawings. Contractor to thoroughly swab, clean and mandrel all existing conduits in existing ducbank system that is intended to have primary cables installed. Conduit mandrel shall be no more than ¼” less than the conduit system under test. Contractor shall certify that all existing conduit systems have been prepped per this specification and are suitable for cable installation prior to installation of medium voltage cables.
3.1.1.2 Keep ends of cables sealed watertight at all times, except when making splices or terminations.
3.1.1.3 No grease, oil, lubricant other than approved pulling compound may be used to facilitate the pulling in of cables.
3.1.1.4 Use pulling eye attached to conductor(s) for pulling-in cables. Cable grip will not be allowed. Seal pulling eye attachment watertight.
4.19 16126-6 394.107.001 SECTION 16126
PRIMARY WIRING - 15KV NOMINAL
3.1.1.5 Pull all cables with a dynamometer or strain gage incorporated into the pulling equipment. Do not pull cables unless the Owner’s Representative is present to observe readings on the dynamometer or strain gage during the time of actual pulling. Do not exceed manufacturer’s recommended maximum strain on cable for a 3 conductor pull (3 single conductor cables).
3.1.2 Terminations and Splices:
3.1.2.1 General: Splice and terminate cable in accordance with manufacturer's approved installation instructions, employing specific tools recommended by the manufacturer.
3.1.2.1.1 Use IEEE 48 Class 1 terminations to terminate cable in wet locations.
3.1.2.1.2 Use IEEE 48 Class 1 terminations to terminate cable inside of outdoor equipment which is not equipped with space heaters (pad mounted switches, pad mounted transformers, etc.).
3.1.2.1.3 Use IEEE 48 Class 1 terminations to terminate cable in dry locations.
3.1.2.1.4 Ground shield at terminations.
3.1.2.1.5 Incorporate solder dam or use other approved method to prevent moisture from entering splices through grounding conductor.
3.1.2.1.6 Contractor to provide and use dead-break elbows at transformer primary bushing wells/inserts.
3.1.3 Arc Proofing: Arc proof feeders installed in a common pull box or manhole as follows:
3.1.3.1 Arc proof new feeders.
3.1.3.2 Arc proof existing feeders that are spliced to new feeders.
3.1.3.3 Arc proof each feeder as a unit with half-lapped layer of 55 mils thick arc proofing tape, random wrapped or laced with glass cloth tape or glass-fiber cord. For arc proofing tape less than 55 mils thick add layers to equivalent of 55 mils thick arc proofing tape.
3.1.4 Identification of Feeders: Identify feeders in manholes, pull boxes and in equipment to which they connect:
4.19 16126-7 394.107.001 SECTION 16126
PRIMARY WIRING - 15KV NOMINAL
3.1.4.1 Install tags on each insulated conductor indicating phase leg. Attach tags with non- ferrous metal wire. Install phase leg tags under arc proofing tapes.
3.1.4.2 Install tags on each feeder indicating feeder number, date installed (month, year), type of cable, voltage rating, size, and manufacturer. Attach tags to feeders with non-ferrous metal wire or brass chain. Install tags so that they are easily read without moving adjacent feeders or require removal of arc proofing tapes.
3.1.5 Phase Relationship: Connect feeders to maintain phase relationship through system. Phase legs of feeders shall match bus arrangements in equipment to which the feeders are connected.
3.2 FIELD QUALITY CONTROL:
3.2.1 High Voltage (Hipot) After Installation Test: Test to verify electrical insulation on installed cables has not been damaged and that leakage current is minimal.
3.2.1.1 Have the cable installation tested by the testing company.
3.2.1.2 Perform test after cable has been installed complete with all splicing, bonding, etc., and prior to placing cable into service.
3.2.1.3 Perform test in the presence of the Owner’s Representative and the Company Field Advisor.
3.2.1.4 Perform Acceptance Test following all National Electrical Testing Association (NETA) and IEEE Standard 400 requirements and all applicable test methods in ICEA and AEIC specifications.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT – PRIMARY WIRING – 15K NOMINAL:
4.1.1 Measurement for Primary Wiring – 15k Nominal shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.19 16126-8 394.107.001 SECTION 16126
PRIMARY WIRING - 15KV NOMINAL
4.2 PAYMENT – PRIMARY WIRING – 15K NOMINAL:
4.2.1 For Primary Wiring – 15k Nominal, not included in other unit or lump sum price items, payment for Primary Wiring – 15k Nominal will be made at the applicable price stated in the Bid.
END OF SECTION
4.19 16126-9 394.107.001 SECTION 16132
CONDUIT
PART 1 – GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Conduit as shown on the Plans, as specified, and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American National Standards Institute (ANSI) Publications:
C80.1 Rigid Steel Conduit, Zinc Coated
C80.3 Electrical Metallic Tubing, Zinc Coated
C80.5 Rigid Aluminum Conduit
1.2.2 National Electrical Manufacturers Association (NEMA) Publications:
FB 1 Fittings, Cast Metal Boxes, and Conduit Bodies for Conduit and Cable Assemblies
RN 1 Polyvinyl Chloride (PVC) Externally Coated Galvanized Rigid Steel Conduit and Intermediate Metal Conduit
TC 2 Electrical Plastic Tubing (EPT) and Conduit (EPC-40 and EPC-80)
TC 3 PVC Fittings for Use with Rigid PVC Conduit and Tubing
1.2.3 National Electrical Contractors Association (NECA) Publication:
Standard of Installation
4.19 16132-1 394.107.001 SECTION 16132
CONDUIT
1.3 SECTION INCLUDES:
a. Rigid steel conduit b. PVC coated rigid steel conduit c. Flexible metal conduit d. Liquid-tight flexible metal conduit e. Electrical metallic tubing f. Nonmetallic conduit g. Flexible nonmetallic conduit h. Electrical nonmetallic tubing i. Fittings and conduit bodies
1.4 RELATED REQUIREMENTS: Section 16011, “Electrical General Requirements”, applies to this Section with additions and modifications specified herein.
1.5 SUBMITTALS: Conduit and fittings (each type).
1.6 DELIVERY, STORAGE, AND HANDLING:
1.6.1 Protect conduit from corrosion and entrance of debris by storing above grade. Provide appropriate covering.
1.6.2 Protect PVC conduit from sunlight.
1.7 PROJECT CONDITIONS:
1.7.1 Verify that field measurements are as shown on the Contract Drawings.
1.7.2 Verify routing and termination locations of conduit prior to rough-in.
1.7.3 Conduit routing when shown on the Contract Drawings are in approximate locations unless dimensioned. Route as required to complete wiring system.
1.8 QUALITY ASSURANCE: In each standard referred to herein, consider the advisory provisions to be mandatory, as though the word “shall” has been substituted for “should” wherever it appears.
1.8.1 Verify routing and termination locations of conduit prior to rough-in.
4.19 16132-2 394.107.001 SECTION 16132
CONDUIT
1.8.2 Conduit routing when shown on the Contract Drawings are in approximate locations unless dimensioned. Route as required to complete wiring system.
1.9 QUALITY ASSURANCE: In each standard referred to herein, consider the advisory provisions to be mandatory, as though the word “shall” has been substituted for “should” wherever it appears.
PART 2 – PRODUCTS
2.1 MATERIALS AND EQUIPMENT: Materials, equipment, and devices shall, as a minimum, meet requirements of UL, where UL standards are established for these items, and requirements of NFPA 70.
2.1.1 Provide conduit types in specific installations as scheduled on Contract Drawings. Conduits that are identified on the Contract Drawings shall be as specified below.
2.2 CONDUIT AND FITTINGS:
2.2.1 Rigid Steel Conduit (Zinc-coated): ANSI C80.1, UL 6.
2.2.2 Rigid Nonmetallic Conduit: PVC Type EPC-40, in accordance with NEMA TC2, or fiberglass conduit in accordance with NEMA TC14.
2.2.3 Intermediate Metal Conduit (IMC): UL 1242, zinc-coated steel only.
2.2.4 Electrical Metallic Tubing (EMT): UL 797, ANSI C80.3.
2.2.5 Electrical Nonmetallic Tubing (ENT): NEMA TC13.
2.2.6 Plastic-coated Rigid Steel and IMC Conduit: NEMA RN1, Type 40 (40 mils thick).
2.2.7 Flexible Metal Conduit: UL 1.
2.2.7.1 Liquid-tight Flexible Metal Conduit, Steel: UL 360.
2.2.8 Fittings for Metal Conduit, EMT, and Flexible Metal Conduit: UL 514B. Ferrous fittings shall be cadmium- or zinc-coated in accordance with UL 514B.
4.19 16132-3 394.107.001 SECTION 16132
CONDUIT
2.2.8.1 Fittings for Rigid Metal Conduit and IMC: Threaded-type. Split couplings unacceptable.
2.2.8.2 Fittings for EMT: Compression type.
2.2.8.3 Fittings for Use in Hazardous Locations: UL 886.
2.2.9 Fittings for Rigid Nonmetallic Conduit: NEMA TC3.
PART 3 - EXECUTION
3.1 INSTALLATION: Electrical installations shall conform to requirements of NFPA 70 and to requirements specified herein.
3.1.1 Hazardous Locations: RGS or PVC coated RGS only. Work in hazardous locations, as defined by NFPA 70, shall be performed in strict accordance with NFPA 70 for particular "Class", "Division", and "Group" of hazardous locations involved. Provide conduit and cable seals where required by NFPA 70. Conduit shall have tapered threads.
3.1.2 Service Entrance Identification: Service entrance disconnect devices, switches, or enclosures shall be labeled or identified as such.
3.1.2.1 Labels: Wherever work results in service entrance disconnect devices in more than one enclosure, as permitted by NFPA 70, each enclosure, new and existing, shall be labeled as one of several enclosures containing service entrance disconnect devices. Label, at minimum, shall indicate number of service disconnect devices housed by enclosure and shall indicate total number of enclosures that contain service disconnect devices. Provide laminated plastic labels. Use lettering of at least 0.25 inch in height, and engrave on black-on-white matte finish. Service entrance disconnect devices in more than one enclosure shall be provided only as permitted by NFPA 70.
3.1.3 Wiring Methods: Provide insulated conductors installed in conduit, except where specifically indicated or specified otherwise or required by NFPA 70 to be installed otherwise. Provide insulated, green equipment grounding conductor in feeder and branch circuits, including lighting circuits. Grounding conductor shall be separate from electrical system neutral conductor. Provide insulated, green conductor for grounding conductors installed in conduit or raceways. Minimum conduit size shall be 1/2 inch in diameter for low voltage lighting and
4.19 16132-4 394.107.001 SECTION 16132
CONDUIT
power circuits. Vertical distribution in multiple story buildings shall be made with metal conduit in fire-rated shafts. Metal conduit shall extend through shafts for minimum distance of 6 inches. Conduit which penetrates fire walls, fire partitions, or floors shall be metallic on both sides of fire walls, fire partitions, or floors for minimum distance of 6 inches.
3.1.3.1 Restrictions Applicable to EMT:
a. Do not use in feeder circuits, unless otherwise indicated.
b. Do not install underground.
c. Do not encase in concrete.
d. Do not use in areas subject to severe physical damage including, but not limited to, mechanical equipment rooms and electrical equipment rooms.
e. Do not use in hazardous areas.
f. Do not use outdoors.
3.1.3.2 Nonmetallic Conduit: Conduit shall not penetrate fire walls, fire partitions, or floors.
3.1.3.3 ENT: ENT may be provided in walls, floors, and ceilings only when protected by thermal barriers identified as having minimum 15-minute finish rating. If ENT is used, provide required thermal barriers, whether indicated or not.
3.1.3.3.1 Following restrictions apply to ENT:
a. Do not route exposed.
b. Do not route above suspended ceilings (i.e., between suspended ceilings and permanent ceilings).
c. Do not use in feeder circuits.
d. Do not install underground.
e. Do not encase in concrete.
4.19 16132-5 394.107.001 SECTION 16132
CONDUIT
f. Do not use in areas subject to severe physical damage including, but not limited to, mechanical equipment rooms, electrical equipment rooms, hospitals, power plants, missile magazines, and other such areas.
g. Do not use in hazardous areas.
h. Do not use outdoors.
i. Do not use in sizes larger than 2 inches.
j. Do not use in penetrating fire rated walls, partitions, etc.
3.1.3.3.2 Restrictions applicable to PVC Schedule 40 and PVC Schedule 80.
a. Do not use in feeder circuits unless otherwise indicated.
b. Do not use in areas subject to severe physical damage including, but not limited to, mechanical equipment rooms, electrical equipment rooms, hospitals, power plants, missile magazines, and other such areas.
c. Do not use in hazardous areas.
d. Do not use in penetrating fire-rated walls or partitions, fire rated floors, etc.
3.1.3.4 Service Entrance Conduit, Overhead: Rigid steel or IMC from service entrance to service entrance fitting or weatherhead outside building.
3.1.3.5 Service Entrance Conduit, Underground: Galvanized rigid steel or steel IMC. Underground portion shall be encased in minimum of 3 inches of concrete and shall be installed minimum 18 inches below slab or grade.
3.1.3.6 Underground Conduit Other Than Service Entrance: Plastic-coated rigid steel; plastic-coated steel IMC; PVC, Type EPC-40; or fiberglass. Convert nonmetallic conduit, other than PVC Schedule 40 or 80, to plastic-coated rigid, or IMC, steel conduit before rising through floor slab; plastic coating shall extend minimum 6 inches above floor.
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3.1.3.7 Conduit in Floor Slabs: Rigid steel; steel IMC; fiberglass, or PVC, Type EPC-40.
3.1.4 Conduit Installation: Unless indicated otherwise, conceal conduit within finished walls, ceilings, and floors. Keep conduit minimum 6 inches away from parallel runs of flues and steam or hot water pipes. Install conduit parallel with or at right angles to ceilings, walls, and structural members where located above accessible ceilings and where conduit will be visible after completion of project.
3.1.4.1 Conduit Through Floor Slabs: Where conduits rise through floor slabs, curved portion of bends shall not be visible above finish slab.
3.1.4.2 Conduit Support: Support conduit by pipe straps, wall brackets, hangers, or ceiling trapeze. Fasten by wood screws to wood; by toggle bolts on hollow masonry units; by concrete inserts or expansion bolts on concrete or brick; and by machine screws, welded threaded studs, or spring-tension clamps on steel work. Threaded C-clamps may be used on rigid steel conduit only. Do not weld conduits or pipe straps to steel structures. Load applied to fasteners shall not exceed one-fourth proof test load. Fasteners attached to concrete ceiling shall be vibration- resistant and shock-resistant. Holes cut to depth of more than 1-1/2 inches in reinforced concrete beams or to depth of more than 3/4 inch in concrete joints shall not cut main reinforcing bars. Fill unused holes. In partitions of light steel construction, use sheet metal screws. In suspended- ceiling construction, run conduit above ceiling. Do not support conduit by ceiling support system. Spring-steel fasteners may be used for lighting branch circuit conduit supports in suspended ceilings in dry locations. Where conduit crosses building expansion joints, provide suitable watertight expansion fitting that maintains conduit electrical continuity by bonding jumpers or other means.
3.1.4.3 Directional Changes in Conduit Runs: Make changes in direction of runs with symmetrical bends or cast-metal fittings. Make field-made bends and offsets with hickey or conduit-bending machine. Do not install crushed or deformed conduits. Avoid trapped conduits. Prevent plaster, dirt, or trash from lodging in conduits, boxes, fittings, and equipment during construction. Free clogged conduits of obstructions.
3.1.4.4 Pull Wire: Install pull wires in empty conduits in which wire is to be installed by others. Pull wire shall be plastic having minimum 200-pound tensile strength. Leave minimum 12 inches of slack at each end of pull wire.
3.1.4.5 Telephone and Signal System Conduits: Install in accordance with specified requirements for conduit and with additional requirement that no length of run shall exceed 150 feet for trade sizes 2 inches and smaller and shall not contain more than two 90-degree bends or
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equivalent unless shown otherwise. In no case shall there be more than four (4) 90-degree bends or equivalent. Provide pull or junction boxes where necessary to comply with these requirements. Inside radii of bends in conduits 1-inch trade size and larger shall be minimum five times nominal diameter. Terminate conduit at bottom edge of backboard or in terminal cabinet with two locknuts and plastic bushing.
3.1.4.6 Conduit Installed in Concrete Floor Slabs: Locate so as not to adversely affect structural strength of slabs. Install conduit within middle 1/3 of concrete slab. Do not stack conduits. Space conduits horizontally minimum three diameters, except at cabinet locations. Curved portions of bends shall not be visible above finish slab. Increase slab thickness as necessary to provide minimum 1-inch cover over conduit. Where embedded conduits cross expansion joints, provide suitable watertight expansion fittings and bonding jumpers. Conduit larger than 1-inch trade size shall be parallel with or at right angles to main reinforcement; when at right angles to reinforcement, conduit shall be close to one of supports of slab. Where nonmetallic conduit is used, raceway must be converted to rigid steel or EMT before rising above floor, unless specifically indicated otherwise.
3.1.4.7 Locknuts and Bushings: Fasten conduits to sheet metal boxes and cabinets with two locknuts where required by NFPA 70, where insulated bushings are used, and where bushings cannot be brought into firm contact with the box; otherwise, use minimum single locknut and bushing. Locknuts shall have sharp edges for digging into wall of metal enclosures. Install bushings on ends of conduits, and provide insulating type where required by NFPA 70.
3.1.4.8 Stub-ups: Provide conduits stubbed up through concrete floor for connection to free-standing equipment with adjustable top or coupling threaded inside for plugs, set flush with finished floor. Extend conductors to equipment in rigid steel conduit, except that flexible metal conduit may be used 6 inches above floor. Where no equipment connections are made, install screwdriver-operated threaded flush plugs in conduit end.
3.1.4.9 Flexible Connections: Provide flexible connections of short length, 6-foot maximum, for recessed and semi-recessed lighting fixtures; for equipment subject to vibration, noise transmission, or movement; and for motors. Provide liquid-tight flexible conduit in wet locations. Provide separate ground conductor across flexible connections.
3.1.4.10 Arrange conduit to maintain headroom and present neat appearance.
3.1.4.11 Cut conduit square using saw or pipe cutter; deburr cut ends.
4.19 16132-8 394.107.001 SECTION 16132
CONDUIT
3.1.4.12 Use conduit hubs or sealing locknuts to fasten conduit to sheet metal boxes in damp and wet locations and to cast boxes.
3.1.4.13 Install no more than equivalent of four (4) 90 degree bends between boxes.
3.1.4.14 Avoid moisture traps; provide junction box with drain fitting at low points in conduit system.
3.1.4.15 Provide suitable fittings to accommodate expansion and deflection where conduit crosses expansion joints.
3.1.4.16 Use suitable caps to protect installed conduit against entrance of dirt and moisture.
3.1.4.17 Ground and bond conduit under as per NEC 250.
3.2 INTERFACE WITH OTHER PRODUCTS:
3.2.1 Unless allowed by enclosure/equipment manufacturer, all conduit penetrations to equipment enclosures shall be on bottom of enclosure.
3.2.2 Install conduit to preserve fire resistance rating of partitions and other elements, using materials and methods necessary to maintain fire resistance rating. .
3.2.3 Route conduit through roof openings for piping and ductwork or provide suitable roof jack with pitch pocket for contractor provided conduit systems. Coordinate location with roofing installation and roofing system construction.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - CONDUIT:
4.1.1 Measurement for Conduit shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.19 16132-9 394.107.001 SECTION 16132
CONDUIT
4.2 PAYMENT - CONDUIT:
4.2.1 For Conduit, not included in other unit or lump sum price items, payment for Conduit will be made at the applicable price stated in the Bid.
END OF SECTION
4.19 16132-10 394.107.001 SECTION 16140
WIRING DEVICES
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Wiring Devices as shown on the Plans, as specified, and/or directed.
1.2 SUBMITTALS:
1.2.1 Product Data: Catalog sheets, specifications and installation instructions.
PART 2 - PRODUCTS
2.1 SWITCHES:
2.1.1 Local Switches, Single Pole: 20A, 120/277 V ac; Bryant’s 4901, Crouse-Hinds/AH’s 1991, General Electric’s GE 5951-1G, Hubbell’s 1121/1221, Leviton’s 1121/1221, Pass & Seymour’s 20AC1, or Woodhead’s 1991.
2.1.2 Local Switches, Double Pole: 20A, 120/277 V ac; Bryant’s 4902, Crouse-Hinds/AH’s 1992, General Electric’s GE5952-1G, Hubbell’s 1222/1122, Leviton’s 1222/1122, Pass & Seymour’s 20AC2, or Woodhead’s 1992.
2.1.3 Local Switches, Three-Way: 20A, 120/277 V ac; Bryant’s 4903, Crouse-Hinds/AH’s 1993, General Electric’s GE5953-1G, Hubbell’s 1223/1123, Leviton’s 1223-2/1123-2, Pass & Seymour’s 20AC3, or Woodhead’s 1993.
2.1.4 Local Switches, Four-Way: 20A, 120/277 V ac; Bryant’s 4904, Crouse-Hinds/AH’s 1994, General Electric’s GE5954-1G, Hubbell’s 1224/1124, Leviton’s 1224-2/1124-2, Pass & Seymour’s 20AC4, or Woodhead’s 1994.
2.2 RECEPTACLES:
2.2.1 Federal Spec./NEMA Grade Receptacles:
a. Single receptacle, NEMA 5-20R (20A, 125 V, 2P, 3W); Bryant’s 5361, Crouse- Hinds/AH’s 5361, General Electric’s GE4102-1, Hubbell’s 5361, Leviton’s 5361, or Pass & Seymour’s 5361.
4.19 16140-1 394.107.001 SECTION 16140
WIRING DEVICES
b. Duplex receptacle, NEMA 5-20R (20A, 125 V, 2P, 3W); Bryant’s 5362, Crouse- Hinds/AH’s 5739-S, General Electric’s GE5362-1, Hubbell’s 5362, Leviton’s 5362, Pass & Seymour’s 5362, or Daniel Woodhead’s 5362 DW.
2.2.2 Ground Fault Interrupter Receptacles: Duplex receptacle rated 20A (NEMA 5-20R), circuit ampacity 20A; Bryant’s GFR53FT, Crouse-Hind/AH’s GF5342, General Electric’s GF5342, Hubbell’s GF 5352, Leviton’s 6899, Pass & Seymour’s 2091S, or Daniel Woodheads 5352GF.
2.3 WALL PLATES:
2.3.1 Stainless Steel Wall Plates: Type 302 stainless steel with satin finish. All areas except finished spaces or wet locations.
2.3.2 Weatherproof/Wet Location Covers: UL 514D type “extra duty”. Thomas & Betts Red Dot Code Keeper type 2CKU or equal.
2.3.3 Finished areas: Polycarbonate.
2.4 NAMEPLATES:
2.4.1 Phenolic Type: Standard phenolic nameplates with 3/16 inch minimum size lettering engraved thereon.
2.4.2 Embossed Aluminum: Standard stamped or embossed aluminum tags, 3/16 inch minimum size lettering, as produced by Seton Name Plate Corp. or Tech Products Inc.
PART 3 - EXECUTION
3.1 INSTALLATION:
3.1.1 Install wiring devices in outlet boxes.
3.1.2 Local Switches:
3.1.2.1 Install local switches rated 20A, 120/277 V ac for switches unless otherwise shown on the drawings or specified.
4.19 16140-2 394.107.001 SECTION 16140
WIRING DEVICES
3.1.2.2 Where more than one switch occurs at same location in a 120 volt system, arrange switches in gangs and cover with one face plate.
3.1.2.3 Install single and double pole switches so that switch handle is up when switch is in the “On” position.
3.1.3 Receptacles:
3.1.3.1 Install Specification Grade receptacles, NEMA 5-20R, 20A, 125 V, 2P, 3W, for duplex receptacles and single receptacles unless otherwise shown on the drawings or specified.
3.1.3.2 Install receptacles with ground pole in the down position.
3.1.4 Wall Plates:
3.1.4.1 Install wall plates on all wiring devices in dry locations, with finish to match hardware in each area.
3.1.5 Weatherproof In-use Covers: Install in-use weatherproof covers on all wiring devices in damp and wet locations.
3.1.6 Nameplates: Provide phenolic or embossed aluminum nameplate for each special purpose receptacle indicating phase, ampere and voltage rating of the circuit. Attach nameplate with rivets or tamperproof fasteners to wall plate or to wall above receptacle. Wall plates may be engraved with required data in lieu of separate nameplates.
3.1.7 Where Contract Drawings call out a classified area all equipment/devices and wiring methods to be suitable for this area per NEC. Refer to Contract Drawings for classified area locations.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT – WIRING DEVICES:
4.1.1 Measurement for Wiring Devices shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.19 16140-3 394.107.001 SECTION 16140
WIRING DEVICES
4.2 PAYMENT – WIRING DEVICES:
4.2.1 For Wiring Devices, not included in other unit or lump sum price items, payment for Wiring Devices will be made at the applicable price stated in the Bid.
END OF SECTION
4.19 16140-4 394.107.001 SECTION 16216
DIESEL EMERGENCY GENERATOR
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials, equipment and accessories for Diesel Emergency Generator, as shown on the Plans, as specified and/or directed.
1.1.2 System shall be complete including , fuel transfer piping, interior fuel sub-base tank, batteries and charger, insulated exhaust piping and muffler, control devices and other equipment and accessories as specified herein and/or as shown.
1.1.3 The equipment for the Diesel Emergency Generator shall include:
a. 200 KW – 480/277 volt - 3 phase - 4 wire diesel generator unit b. interior sub-base fuel tank, +/- 425 gallon capacity c. batteries and charger d. insulated exhaust piping and muffler and ceiling support system e. integral heat exchanger cooling system f. installation and initial start-up and training
1.1.4 The work shall also include all controls, accessories, appurtenances or other work required for a complete operating installation.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only and shall be the most current version.
1.2.1 American Institute of Steel Construction (AISC) Publication:
Specification for the Design, Fabrication and Erection of Structural Steel for Buildings
1.2.2 American National Standards Institute, Inc. (ANSI) Publications:
B1.1 Unified Inch Screw Threads (UN and UNR Thread Form)
B2.1 Pipe Threads (Except Dryseal)
6.19 16216-1 394.107.001 SECTION 16216
DIESEL EMERGENCY GENERATOR
B15.1 Safety Standard for Mechanical Power Transmission Apparatus
B16.1 Cast Iron Pipe Flanges and Flanged Fittings (Class 25, 125, 250, and 800)
B16.3 Malleable Iron, Threaded Fittings (Class 150 and 300)
B16.5 Steel Pipe Flanges and Flanged Fittings (Including Ratings for Class 150, 300, 400, 600, 900, 1500, and 2500)
B16.9 Factory-Made Wrought Steel Buttwelding Fittings
B16.11 Forged Steel Fittings, Socket-Welding and Threaded
B16.39 Malleable Iron, Threaded Pipe Unions (Class 150, 250 and 300)
B18.2.1 Square and Hex Bolts and Screws (Including Hex Cap Screws and Lag Screws)
B18.2.2 Square and Hex Nuts
B31.1 Power Piping, B31.1.0a-1971, B31.1.0b-1971, B31.1.0c- 1972, B31.1.0d-1972
B40.1 Gauges-Pressure Indicating Dial Type-Elastic Element
C37.13 Low-Voltage AC Power Circuit Breakers Used in Enclosures
C37.16 Preferred Ratings, Related Requirements, and Application Recommendations for Low-Voltage Power Circuit Breakers and AC Power Circuit Protectors
C37.17 Trip Devices for AC and General Purpose DC Low-Voltage Power Circuit Breakers
6.19 16216-2 394.107.001 SECTION 16216
DIESEL EMERGENCY GENERATOR
C57.13 Requirements for Instrument Transformers
Z55.1 Gray Finishes for Industrial Apparatus and Equipment
1.2.3 American Society of Mechanical Engineers (ASME) Publication:
ASME Boiler and Pressure Vessel Code: Section VIII - Pressure Vessels
1.2.4 American Society for Testing and Materials (ASTM) Publications:
A53 Pipe, Steel, Black and Hot-Dipped, Zinc-Coated Welded and Seamless
A126 Gray Iron Castings for Valves, Flanges, and Pipe Fittings
A181 Forgings, Carbon Steel, for General-Purpose Piping
A193 Alloy-Steel and Stainless Steel Bolting Materials for High- Temperature Service
A194 Carbon and Alloy Steel Nuts for Bolts for High-Pressure and High-Temperature Service
A234 Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures
A307 Carbon Steel Externally Threaded Standard Fasteners
B8 Concentric-Lay-Stranded Copper Conductors, Hard, Medium-Hard or Soft
B33 Tinned Soft or Annealed Copper Wire for Electrical Purposes
B230 Aluminum 1350-H19 Wire for Electrical Purposes
B231 Concentric-Lay-Stranded Aluminum 1350 Conductors
6.19 16216-3 394.107.001 SECTION 16216
DIESEL EMERGENCY GENERATOR
B317 Aluminum-Alloy Extruded Bar, Rod, Pipe, and Structural Shapes for Electrical Purposes (Bus Conductor)
B609 Aluminum 1350 Round Wire, Annealed and Intermediate Tempers, for Electrical Purposes
D178 Rubber Insulating Matting
D1785 Poly (Vinyl Chloride) (PVC) Plastic Pipe, Schedules 40, 80, and 120
D2466 Poly (Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 40
D2467 Socket-Type Poly (Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 80
D2564 Solvent Cements for Poly (Vinyl Chloride) (PVC) Plastic Pipe and Fittings
1.2.5 American Water Works Association (AWWA) Publication:
C601 Standard for Disinfecting Water Mains
1.2.6 Diesel Engine Manufacturers Association (DEMA) Publication:
Standard Practices for Stationary Diesel and Gas Engines
1.2.7 Institute of Electrical and Electronic Engineers (IEEE) Publications:
32 Requirements, Terminology, and Test Procedure for Neutral Grounding Devices
115 Test Procedures for Synchronous Machines
126 Internal Combustion Engine-Generator Units, Recommended Specification for Speed Governing of
6.19 16216-4 394.107.001 SECTION 16216
DIESEL EMERGENCY GENERATOR
421 Standard Criteria and Definitions for Excitation Systems for Synchronous Machines
1.2.8 Insulated Cable Engineers Association (ICEA) Publications:
S-19-81 Rubber Insulated Wire and Cable for the Transmission and Distribution of Electrical Energy
S-61-402 Thermoplastic-Insulated Wire and Cable for the Transmission and Distribution of Electrical Energy
S-66-524 Cross-Linked-Thermosetting-Polyethylene- Interim Insulated Wire and Cable for the Standard No. 1 Transmission and Distribution of Electrical Energy
S-68-516 Cables Rated 0-35,000 Volts and Having Interim Ozone-Resistant Ethylene-Propylene Rubber Standard No. 1 Insulation
1.2.9 Manufacturers Standardization Society of the Valve and Fittings Industry (MSS) Publication:
SP-83 Carbon Steel Pipe Unions, Socket-Welding and Threaded
1.2.10 National Electrical Manufacturers Association (NEMA) Publications:
AB 1 Molded Case Circuit Breakers
ICS 1 General Standards for Industrial Control and Systems
LA 1 Surge Arresters
MG 1 Motors and Generators
PV 5 Constant-Potential-Type Electric Utility (Semiconductor Static Converter) Battery Chargers
SG 3 Low-Voltage Power Circuit Breakers
6.19 16216-5 394.107.001 SECTION 16216
DIESEL EMERGENCY GENERATOR
ST 20 Dry-Type Transformers for General Applications
TR 27 Commercial, Institutional and Industrial Dry-Type Transformers
1.2.11 National Fire Protection Association (NFPA) Standards:
30 Flammable and Combustible Liquids Code
37 Standard for the Installation and Use of Stationary Combustion Engines and Gas Turbines
70 National Electric Code
110 Emergency and Standby Power Systems
325 Fire Hazard Properties of Flammable Liquids, Gases and Volatile Solids
495 Explosive Materials Code
1.2.12 Tubular Exchanger Manufacturer's Association (TEMA) Publication:
Standards of Tubular Exchanger Manufacturer's Association
1.2.13 Underwriters Laboratories, Inc. (UL) Publications:
UL 429 Electrically Operated Valves
UL 2200 Standard for Stationary Engine Generator Assemblies
1.3 RELATED REQUIREMENTS: Section 16011, "Electrical General Requirements", applies to this Section with additions and modifications specified herein.
1.4 SUBMITTALS:
1.4.1 Shop Drawings: Submit for the following:
6.19 16216-6 394.107.001 SECTION 16216
DIESEL EMERGENCY GENERATOR
a. Engine Generator b. Subbase Fuel Tank c. Silencer d. Generator Ancillary Equipment e. Schematic showing interconnection of all generator system equipment to include generator, ATS, and support equipment
1.4.2 Engine Generator Submittal: Submittal shall contain as a minimum:
a. drawings of generator unit showing dimensions and weights b. tabulated data on: 1. Make of engine. 2. Number of cylinders. 3. Bore, liters (inches). 4. Stroke, liters (inches). 5. Piston displacement, liters (cubic inches). 6. Piston speed, liters per minute (feet/min.), @ rated rpm. 7. BMEP @ rated KW output. 8. Make and type of generator. 9. Generator electrical rating, KVA or KW @ 0.8 power factor. 10. Number and type of bearings. 11. Exciter type. 12. Generator insulation class and temperature rise. 13. Parts and service support. 14. Engine manufacturer's certified engine BHP curve and certified gen-set fuel consumption. 15. Heat exchanger system. c. installation drawings showing installation requirements d. spare parts list, manufacturer's operation and maintenance manuals for engine generator and major accessories e. training schedule for Owner's personnel instruction
1.4.3 Operation and Maintenance Manual: Furnish an operations and maintenance manual for each component of the system . The manual shall include: wiring and control diagrams with data to explain detailed operation and control of each item of equipment; a control sequence describing start-up, operation and shutdown; description of the function of each component; the procedure for starting; the procedure for operating; shutdown instructions; installation
6.19 16216-7 394.107.001 SECTION 16216
DIESEL EMERGENCY GENERATOR
instructions; maintenance instructions; lubrication schedule; safety precaution; diagrams; performance data; and parts list. The parts list shall indicate the sources of supply, recommended spare parts, and the service organization which is reasonably convenient to the project site.
1.5 QUALITY ASSURANCE: In each standard referred to herein, consider the advisory provisions to be mandatory, as though the word "shall" has been substituted for "should" wherever it appears.
1.5.1 Operating Experience Requirements: Engines installed in the power plant shall meet all of the operating experience requirements listed below.
a. Only stationary electric generation service is considered as equivalent experience. Engines driving pumps or compressors or in marine propulsion or railroad service are not acceptable.
b. Only experience on the same engine model is acceptable. Engine model is considered to be a given series or class of identical bore and stroke and of the same type of engine, such as in-line or vee. In-line and vee engines with identical bore and stroke are considered as two separate models of engines.
c. Only experience at the identical rotative speed as that which is offered is acceptable.
d. Only experience at the identical or higher brake mean effective pressure as that which is offered is acceptable.
e. Only experience with oil and dual fuel engines is acceptable.
1.5.2 Engine/Gen-Set Unit: Unit shall be capable of continuous full power service at rated output for duration of standby service. Engine/generator shall be product of one manufacturer, and the manufacturer and its authorized dealer shall have sole responsibility for the performance of the diesel engine/ generator set and its accessories. Diesel engine/generator shall be completely shop assembled, tested and adjusted prior to shipment.
1.6 SERVICES:
1.6.1 The manufacturer shall furnish a qualified local field representative to inspect and/or adjust the equipment after installation, to supervise its initial operation and to train plant personnel in operation and maintenance of the equipment specified. Service organization shall be located within 24-hour travel time of the project.
6.19 16216-8 394.107.001 SECTION 16216
DIESEL EMERGENCY GENERATOR
1.6.2 After the emergency generator system is installed and proved operational, the manufacturer shall provide factory trained service technicians for a minimum of 8 hours of operation and maintenance training of the Owner's plant personnel of the generator system as installed.
1.7 WARRANTY: After equipment is installed and operational, the Contractor shall furnish a two-year warranty against defects in material and workmanship. Warranty coverage shall include all parts, labor and travel expenses.
PART 2 - PRODUCTS
2.1 MATERIALS AND EQUIPMENT: Materials, equipment and devices shall, as a minimum, meet requirements of UL, where UL standards are established for those items, and requirements of NFPA 70.
2.1.1 Generator assembly shall be UL 2200 listed.
2.2 DIESEL ENGINE/GENERATOR SET:
2.2.1 Rating: The AC engine/generator set, shall be rated by the manufacturer for standby operation at 200 KW, 250 KVA at 0.8 PF, 60 Hz, 1800 rpm for use with a 480/277 volt AC, 3 phase, 4-wire system.
2.2.1.1 The generator set manufacturer shall verify the diesel engine as capable of driving the generator with all accessories in place and operating, at the generator set KW rating after de- rating for the range of temperatures expected in service and the altitude of the installation.
2.2.1.2 Voltage regulation shall be ±0.5 percent of rated voltage for any constant load between no load and rated load, and frequency regulation shall be isochronous from steady state no load to steady state rated load.
2.2.1.3 Random Voltage Variation: The cyclic variations in RMS voltage shall not exceed ±0.5 percent of rated for constant loads from no load to rated load, with constant ambient and operating temperature.
2.2.1.4 Random Frequency Variation: Speed variations for constant loads from no load to rated load shall not exceed ±0.25 percent of rated speed, with constant ambient and operating temperature.
6.19 16216-9 394.107.001 SECTION 16216
DIESEL EMERGENCY GENERATOR
2.2.1.5 Total Harmonic Distortion: The sum of AC voltage waveform harmonics, from no load to full linear load, shall not exceed 5 percent of rated voltage (L-N, L-L, L-L-L) and no single harmonic shall exceed 3 percent of rated voltage.
2.2.1.6 Telephone Influence Factor: TIF shall be less than 50 per NEMA MG1-22.43.
2.2.1.7 The diesel engine/generator set shall be capable of picking up 100% of nameplate KW and power factor, less applicable de-rating factors, in one step with the engine/generator set at operating temperature, in accordance with NFPA Standard 110, Paragraph 5-13.2.6.
2.2.1.8 Motor starting KVA shall be a minimum as required, based upon a sustained RMS voltage drop of no more than 10% of no load voltage with the specified load KVA.
2.2.1.8.1 Submit starting calculations for the generator based on the following:
a. Maximum starting voltage dip – 20% b. Maximum peak voltage dip – 20% c. Maximum frequency dip – 10% d. Minimum load rated capacity – 30%
2.2.1.8.2 Generator shall be capable of starting and operating all of the following required loads at the solid waste facility in compliance with the above referenced criteria:
Step 1: 25 HP Pump on VFD (Leachate PS) Step 1: 50 kVA linear load at 0.85pf (Leachate PS) Step 2: 25 HP Pump on VFD (Leachate PS) Step 2: 40 kVA linear load at 0.85 pf (four siderisers) Step 3: 5 HP Pump on VFD (Leachate PS) Step 3: 30 kVA linear load at 0.85 pf (three siderisers) Step 4: 20 kVA linear load at 0.85 pf (two siderisers) Step 5: 25 0HP (Future compressor, blower, pump, etc.)
2.3 AC GENERATOR, REGULATOR AND EXCITER UNIT: The AC generator, exciter and voltage regulator shall be designed and manufactured by the engine/generator set manufacturer as a complete generator system. The generator shall meet all requirements of NEMA MG-1, Part 22, in design, performance and factory test procedures. The generator and regulator will be C.S.A. listed. The regulator shall be factory wired and tested with the generator. Cast iron end brackets and fabricated steel frames shall be used. The unit shall be fully guarded per NEMA MG-1-1.25. Bearings shall be pre-lubricated, shielded, ball-type with
6.19 16216-10 394.107.001 SECTION 16216
DIESEL EMERGENCY GENERATOR
provisions for adding and/or changing grease through extended supply and relief tubes. Minimum B-10 bearing life shall be 40,000 hours for single bearing units.
2.3.1 The AC generator shall be synchronous, four pole, revolving field, drip-proof construction, single pre-lubricated sealed bearing, air cooled by a direct drive centrifugal blower fan, and directly connected to the engine with flexible drive disc(s). The armature shall have skewed laminations of insulated electrical grade steel, two-thirds pitch windings. The rotor shall have amortisseur (damper) windings, layer wound mechanically wedged winding construction. The rotor shall be dynamically balanced. The exciter shall be brushless, three phase, with full wave silicon diodes mounted on the rotating shaft and a surge suppressor connected in parallel with the field winding. Field discharge resistors shall not be acceptable. Systems using three- wire solid-state devices (such as SCRs or transistors) mounted on the rotor shaft shall not be acceptable.
2.3.2 AC output leads shall be brought out to field connection bus bars accessible through removable plates on either side of a sheet metal output box.
2.3.3 All insulation system components shall meet NEMA MG1 standard temperature limits for Class H insulation system. Actual temperature rise measured by resistance method at full load shall not exceed 105 degrees Centigrade to provide additional allowance for internal hot spots. The main generator and exciter insulation systems must be suitably impregnated for operation in severe environments for resistance to sand, salt, and sea spray.
2.3.4 A permanent magnet generator (PMG) shall provide excitation power to the automatic voltage regulator for immunity from voltage distortion caused by nonlinear SCR controlled loads on the generator. The PMG shall sustain main field excitation power for optimum motor starting and to sustain short circuit current for selective operation and coordination of system over- current devices.
2.3.5 The automatic voltage regulator shall be temperature compensated, solid-state design and include overvoltage and overexcitation protection functions. The voltage regulator shall be equipped with three phase RMS sensing. The regulator shall control buildup of AC generator voltage to provide a linear rise and limit overshoot. Overvoltage protection shall sense the AC generator output voltage and in the event of regulator failure or loss of reference, shut down regulator output on a sustained overvoltage of one (1) second duration. Overexcitation protection shall sense regulator output and shut down regulator output if overloads exceed ten (10) seconds duration. Both overvoltage and overexcitation protection shutdowns shall be latched, requiring the AC generator to be stopped for reset. The regulator shall include an under frequency roll-off torque-matching characteristic, which shall reduce output voltage in proportion
6.19 16216-11 394.107.001 SECTION 16216
DIESEL EMERGENCY GENERATOR
to frequency below a threshold of 58-59 Hz (48-49 Hz on 50 Hz system). The torque-matching characteristic shall include differential rate of frequency change compensation to use maximum available engine torque and provide optimal transient load response. Regulators which use a fixed volts per hertz characteristic are not acceptable.
2.4 ENGINE/GENERATOR SET CONTROL: A unit mounted NEMA 1 enclosed control panel shall be installed on the generator set with vibration isolators. The control panel shall contain controls for the operation of the engine and the generator.
2.4.1 The panel shall have a manual switch to start and stop the engine. When the switch is in the run position, the engine shall start and run, when in stop position the engine shall stop.
2.4.2 The control panel shall include a cycle cranking function. The cranking cycle, nonadjustable, shall consist of an automatic crank period of approximately 15 seconds duration followed by a rest period of approximately 15 seconds duration. Cranking shall cease upon engine starting and running. Two means of cranking termination shall be provided, one as a backup to the other. Failure to start after three cranking cycles (75 seconds) shall shut down and lock out the engine, and visually indicate an over-crank shutdown on the panel.
2.4.3 The control panel shall shut down and lock out the engine upon failing to start after the specified time due to over-crank, over-speed, low lubricating oil pressure or high engine temperature.
2.4.4 The control panel shall provide a twelve light engine monitor annunciator; one red light for each of the four shutdowns (except the remote manual stop), and one yellow light each for the high engine temperature and low engine oil pressure pre-alarms, and one green run light. The control panel monitor shall include: a flashing red light to indicate the generator set is not in automatic start mode, a yellow light to indicate low coolant temperature, a yellow light to indicate low fuel, and two red lights for auxiliary use (for a total of twelve). A panel mounted switch shall reset the engine monitor and test all the lamps. The engine/generator set starting battery(ies) shall power the monitor. Operation of shutdown circuits shall be independent of indication and pre-alarm circuits. A common alarm contact for external connection to an audible alarm shall be provided.
2.4.5 The control panel shall provide a low coolant level shutdown, which shall be indicated as a high engine temperature fault.
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DIESEL EMERGENCY GENERATOR
2.4.6 The control panel shall include surge suppression for protection of solid state components. A front control panel illumination lamp with On/Off switch shall be provided. Control panel mounted indicating meters and devices shall include: engine oil pressure gauge, coolant temperature gauge, DC voltmeter, and running time meter (hours); voltage adjusting rheostat, locking screwdriver type, to adjust voltage ±5 percent from rated value; analog AC voltmeter, dual range, 90 degree scale, 2 percent accuracy; analog AC ammeter, dual range, 90 degree scale, 2 percent accuracy; analog frequency meter, 45-65 Hz, 90 degree scale, ±0.6 Hz accuracy; seven position phase selector switch with Off position to allow meter display of current and voltage in each generator phase.
2.4.7 Provisions shall be made for indication of customer-specified alarm or shutdown conditions as shown on the drawings. Labeling of the customer-specified alarm or shutdown condition shall be of the same type and quality as the above-specified conditions. The non- automatic indicating lamp shall be red, and shall flash to indicate that the generator set is not to automatically respond to a command to start from a remote location. In addition, provide four sets (4) N.O. and (4) N.C. contacts for each of the following: engine run, utility power on, generator in test, or as required for control/status of auxiliary signals as required.
2.5 ENGINE: The diesel engine shall be designed specifically for generator set duty. The engine shall be 4 cycle, diesel fueled, direct injection, with forged steel crankshaft and connecting rods. The cylinder block shall be cast iron with replaceable wet liners, and have four valves per cylinder. Design shall be no less than 6 cylinders with a minimum displacement of 855 cubic inches, turbocharged and after-cooled where required by the generator set manufacturer. Two cycle engines are not acceptable.
2.5.1 An electric governor consisting of a magnetic pickup speed sensor, adjustable electronic control, and an electric actuator mounted integrally with the fuel pump, shall provide automatic engine/generator set frequency regulation adjustable from isochronous to 5 percent droop. Governors using external throttle linkages shall not be acceptable.
2.5.2 The engine shall be cooled by a unit mounted coolant pump and thermostat temperature control. The cooling system shall be rated for full rated load operation in 122 degrees F (50 degrees C) ambient conditions. The cooling capability of the generator set shall be demonstrated by prototype tests on a representative generator set model. These tests will be conducted by the generator set manufacturer. The engine shall be equipped with an engine driven, centrifugal- type water circulating pump and thermostatic valve to maintain the engine at recommended temperature level. The engine portion of the cooling system shall be filled with 50/50 ethylene
6.19 16216-13 394.107.001 SECTION 16216
DIESEL EMERGENCY GENERATOR
glycol/water mixture by the equipment supplier. Rotating parts shall be guarded against accidental contact. Provide manually operated relief valves at all high points in coolant piping system.
2.6 ENGINE ACCESSORY EQUIPMENT: The engine generator set shall include the additional engine accessories as follows:
2.6.1 A 24-volt DC electric starter capable of three complete cranking cycles without overheating, before over-crank shutdown (75 seconds).
2.6.2 Engine driven positive displacement, mechanical, full pressure, lubrication oil pump. Full flow lubrication oil filters with replaceable spin-on canister elements and dipstick oil level indicator.
2.6.3 An engine driven, mechanical, positive displacement fuel pump. Fuel filter with replaceable spin-on canister element. Replaceable dry element air cleaner with restriction indicator. Flexible fuel lines, supply and return.
2.6.4 Engine mounted and driven 24-volt DC battery charging alternator, 45 ampere minimum, and solid-state voltage regulator.
2.6.5 Base: The engine/generator set shall be mounted on a heavy duty steel base to maintain proper alignment between components. The engine/generator set shall incorporate a corrosion resistant battery tray with battery hold-down clamps within the base rails. Provisions for stub up of electrical and fuel connections shall be within the footprint of the generator set base rails.
2.6.6 Oil drain and coolant drain lines shall be extended to outside of generator support steel base for ease of maintenance purposes.
2.7 GENERATOR SET AUXILIARY EQUIPMENT:
2.7.1 Generator main circuit breaker, mounted and wired, UL listed, 100% rated molded case thermal-magnetic type, rated at 400A amps, adjustable trip, 3-pole, 480 volt.
2.7.2 Engine mounted, thermostatically controlled, coolant heater for the engine. The heater shall be rated per manufacturer’s requirements, 208V volt, single phase, 50/60 Hz.
6.19 16216-14 394.107.001 SECTION 16216
DIESEL EMERGENCY GENERATOR
2.7.3 Fuel Tank: The UL listed double walled sub-base fuel tank shall be a standard product of the manufacturer of the engine/generator set. Pump and controls shall be as specified in the submittal literature. The tank shall be maximum size permissible up to 425 gallon capacity, field installed in the sub-base of the generator set with engine supply and return lines pre-plumbed. Tank shall have rupture basin and fittings for vent, supply and return piping. The fuel day tank shall be constructed of painted aluminized steel, welded construction and pressure tested to 5 psi. Sub-base tank shall have replaceable fuel filter.
- System Ready (green) - AC and DC power available - High Fuel (red) - Pump shutdown and close N/O dry contacts - Low Fuel (red) - Pump runs and closes N/O dry contacts - Low Fuel Shutdown (red) - Closes N/O contacts - Overflow to Basin (red) - Pump shutdown and N/O dry contacts - One option lamp (red) - With N/O and N/C dry contacts - Pump Running (green) - Leak detection
2.7.4 Exhaust muffler shall be provided, size and type as recommended by the generator set manufacturer. The muffler shall be critical silence grade. Flexible exhaust connection shall be provided for connection between the engine exhaust manifold and exhaust line. System shall be in compliance with applicable codes and standards. An exhaust system condensation trap with manual drain valve to trap and drain off exhaust condensation and to prevent condensation from entering the engine shall be installed on the muffler. Interior muffler and exhaust piping shall be insulated with a 1.5-inch thick layer of ceramic fiber blanket with minimum 2,000°F rating followed by a layer of 1-inch thick needled fiberglass fabricated into a removable insulation blanket using a silicone glass cloth as the finished surface. The average sound level shall be 88 dB(A). Provide ASTM A778 Schedule 10, 304-stainless steel pipe with welded fittings per ASTM A774 for generator exhaust pipe, sizes per generator equipment manufacturer’s recommendations. Exhaust tubing (stainless or otherwise) is not acceptable. Provide non- combustible wall thimble.
2.7.5 Spring vibration isolators, quantity and type as recommended by the generator set manufacturer for field installing the generator set unit on a concrete foundation.
2.7.6 Starting and Control Batteries: Starting batteries 24 volt DC, sized as recommended by the generator set manufacturer, shall be supplied with battery cables and connectors.
6.19 16216-15 394.107.001 SECTION 16216
DIESEL EMERGENCY GENERATOR
2.7.7 Battery Charger: A 10 amp voltage regulated battery charger shall be provided for each engine/generator set. Charger shall be equipped with float, taper and equalize charge settings. Operational monitors shall provide visual output along with individual Form C contacts rated at 4 amps, 120 VAC, 30 VDC for remote indication of:
Loss of AC power - red light Low battery voltage - red light High battery voltage - red light Power On - green light (no relay contact)
2.7.8 Provide an automatically controlled load bank. Size load bank to provide a minimum of 50% generator rated kW load. Unit shall utilize current transformers to measure generator load. Unit shall be capable of manually and automatically selecting resistive load elements in a minimum of 3 steps. Controls and appurtenances necessary for automatically selecting resistive load elements based on generator loading shall be provided. Install on air exhaust end of generator unit such that it doesn’t interfere with field installed ductwork that will be installed from the generator to the air exhaust system building louver. Provide automatic controls that will de-energize the load bank, should a transfer to emergency power signal be indicated from the automatic transfer switch.
2.7.9 Provide interstitial space leak detection, electronic level detection, alarm relay for leak detection.
2.7.10 Spill Kit: Provide cabinet in generator area for cleaning spilled petroleum products. Provide petroleum absorbent 12” x 12” pads (minimum 50), pillows (minimum 10), and 6’ snakes (minimum 4) as manufactured by PIG, or equal.
2.8 SYSTEM AUXILIARIES:
2.8.1 Automatic transfer switch as specified in Section 16262.
2.8.2 Emergency Shut Off: Provide an outdoor rated push-to-open turn and pull to reset emergency shut off switch to remotely stop and de-energize emergency generator. Provide outside of generator room in location to be determined by Owner and Owner’s Designated Representative.
6.19 16216-16 394.107.001 SECTION 16216
DIESEL EMERGENCY GENERATOR
PART 3 - EXECUTION
3.1 INSTALLATION: Installation shall conform to the requirements of NFPA 70 and manufacturer's recommendations.
3.1.1 New Generator: Contractor shall install spring type vibration isolators on the concrete foundation and shall mount the new diesel generator on them.
3.1.2 Fuel System: Contract No. 1C to provide fuel piping and all required vent piping from diesel generator to building exterior.
3.1.3 Exhaust System: Contract No. 1B to provide complete exhaust system (silencer, piping, insulation, wall thimble, flexible connection at unit). Contract No. 1C to install complete exhaust system as shown on contract drawings. Install new rod hangers from structural framing of the ceiling, span minimum of two ceiling joists per support, and hang new muffler and steel exhaust piping. Install 2'-0"± long high temperature flexible connector from generator engine's exhaust to muffler inlet. Install exhaust thimble to building wall, install steel sleeve, exhaust piping and exterior end cap. Install high temperature fibrous flexible insulation in space between wall opening and exhaust piping to seal opening weathertight. Install high temperature insulation on muffler and exhaust piping. Install protective jacket over the insulation.
3.2 START-UP: Provide the services of competent technicians regularly employed by the supplier or manufacturer of the diesel emergency generator system to ensure proper operation of the system during start-up. Services shall include calibration of field devices, adjustments to controlled systems and any other services required to prepare the system for field testing and normal operation.
3.2.1 Adjustments: Adjust controls and equipment to maintain the conditions indicated, to perform the functions indicated and to operate in the sequence specified.
3.3 TESTING: Contractor shall fill sub-base tank with diesel fuel and shall refill tanks after completion of testing, commissioning and after substantial completion. The Contractor shall submit two copies of the operation and maintenance manual and two copies of a test plan to the Owner not less than 14 days prior to acceptance testing. Test plan shall, as a minimum, indicate how the system is to be tested, what variables will be monitored during the test and what criteria for acceptance should be used.
6.19 16216-17 394.107.001 SECTION 16216
DIESEL EMERGENCY GENERATOR
3.3.1 Field Testing: The Contractor shall test the diesel emergency generator system in service to demonstrate conformance with the Contract Requirements. Test controls through every cycle of operation, simulating actual operating conditions as much as possible. Provide the Owner a minimum of one week's advance notice prior to proposed start-up. Test unit under load for a minimum of one hour.
3.4 INSTRUCTING OPERATING PERSONNEL: Upon completion of the work, and after successful acceptance testing, provide instruction to the Owner in the proper operation and maintenance of each device, or indicated system. The period of instruction shall be for not less than one (1) 8-hour working day and shall be in addition to start-up service time. Prior to any instruction sessions, the Contractor shall submit a written proposed outline of material to be covered with a proposed time schedule. The outline and schedule shall be subject to review and approval by the Owner who shall have the right to modify said outline and schedule. Contractor shall furnish outline and schedule a minimum of 3 weeks prior to proposed starting date of any training.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - DIESEL EMERGENCY GENERATOR:
4.1.1 Measurement for Diesel Emergency Generator shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - DIESEL EMERGENCY GENERATOR:
4.2.1 For Diesel Emergency Generator, not included in other unit or lump sum price items, payment for Diesel Emergency Generator will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 16216-18 394.107.001 SECTION 16262
AUTOMATIC TRANSFER SWITCHES
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Automatic Transfer Switches, as shown on the Plans, as specified, and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 Federal Standard (Fed. Std.):
595A Colors & Change Notices 1 thru 6
1.2.2 Institute of Electrical and Electronics Engineers (IEEE) Standard:
472 Guide for Surge Withstand Capability (SWC) Tests
1.2.3 National Electrical Manufacturers Association (NEMA) Standards:
ICS 1 General Standards for Industrial Control and Systems
ICS 2 Standards for Industrial Control Devices, Controllers and Assemblies
ICS 4 Terminal Blocks for Industrial Control Equipment and Systems
ICS 6 Enclosures for Industrial Controls and Systems
1.2.4 National Fire Protection Association (NFPA) Publication:
70 National Electrical Code
6.19 16262-1 394.107.001 SECTION 16262
AUTOMATIC TRANSFER SWITCHES
1.2.5 Underwriters Laboratories, Inc. (UL) Publication:
1008 Automatic Transfer Switches
1.3 SUBMITTALS, FOR AUTOMATIC TRANSFER SWITCH (ATS) :
1.3.1 Shop Drawings: Submit for ATS. Include certified outline, electrical ratings, general arrangement, and detail drawings.
1.3.2 Certificates of Conformance: Submit for ATS as proof of compliance with UL and NEMA standards as specified. Certificates are not required if manufacturer's published data submitted and approved reflect a UL listing and conformance with applicable publications of NEMA.
1.3.3 Certified Test Reports: Submit for each rating of ATS, the reports of tests required by UL 1008 and by the additional requirements listed below. The proof of listing by UL shall be submitted and will be acceptable evidence that the ATS conforms to UL requirements.
1.3.3.1 Withstand and Closing Tests Above UL-1008: The ATS shall be rated for use on a circuit having an available short circuit current of 65 KAIC amperes RMS symmetrical at 20 percent power factor for a duration of 3 cycles when coordinated with molded case circuit breakers, 10 cycles when coordinated with power circuit breakers, and 0.5 cycle when coordinated with current limiting fuses. The withstand and closing tests shall be conducted at full rated system voltage in accordance with UL-1008. The 3- and 10-cycle tests shall be conducted without contact damage.
1.3.3.2 Dielectric Withstand Test: The dielectric withstand test shall be repeated in accordance with UL-1008, after the withstand test specified in paragraph titled "Withstand and Closing Tests Above UL-1008".
1.3.3.3 Non-Welding of Contacts: Automatic transfer switches shall be rated for non-welding of contacts when used with the feeder overcurrent devices indicated on the drawings and with the available fault current specified herein.
1.3.4 Operations and Maintenance Manual: Submit for ATS.
6.19 16262-2 394.107.001 SECTION 16262
AUTOMATIC TRANSFER SWITCHES
PART 2 - PRODUCTS
2.1 AUTOMATIC TRANSFER SWITCH (ATS): Provide automatic transfer switch with the number of poles, amperage, voltage, and withstand ratings as indicated. Transfer switch shall conform to UL 1008 as a recognized component for emergency systems, rated for all classes of loads when installed in an unventilated enclosure. Electrical operation shall be accomplished by a non-fused momentarily energized solenoid direct operating or electric motor operated mechanism or stored energy operator. Mechanical locking in each direction shall be provided. Operation shall be double throw switching where normal and emergency contacts operate with no intentional delay in mid position.
2.1.1 Accessories: A separately mounted control unit shall include:
a. Adjustable, time delay to override momentary dips in normal power source.
b. Phase voltage supervision of three phases of the normal source.
c. Voltage/frequency lockout relay with 90 percent pick-up nominal, to prevent premature transfer.
d. System test switch, momentary type. Load or No load test switch.
e. Engine starting control contacts, one normally closed and one normally open.
f. Auxiliary pilot contacts rated 10 amperes at 480 volts a.c.
g. Adjustable retransfer time delay to normal power source.
h. Full-rated neutral
i. Adjustable time delay on shutdown of engine-generator after transfer of the load to "normal.
j. Pilot lights or keypad to indicate source to which the load is connected.
k. Adjustable center off position to allow
6.19 16262-3 394.107.001 SECTION 16262
AUTOMATIC TRANSFER SWITCHES
l. ATS shall be microprocessor controlled including the following specifications: real- time display of ATS status, synchronous logic for disturbance free transfer, voltage unbalance, test modes, daylight-savings adjustment, opto isolated inputs, voltage and frequency sensing.
m. Adjustable automatic exerciser clock system. Minimal settings shall include day, time, duration.
n. Coordinate controls with generator load bank system. Provide all necessary interconnecting conductors and conduit for a complete operational system.
2.1.2 Onan, Kohler, Zenith, ASCO, or approved equal.
2.1.3 Ratings:
a. Voltage: 480/277 volts
b. Number of Phases: Three
c. Number of Wires: Four
d. Frequency: 60 HZ
e. Number of Switched Poles: Three
f. Continuous Current Rating: or 400 amperes.
g. ATS Withstand and Closing Rating: Rated to withstand and close in on an available fault or short circuit current of amperes, RMS symmetrical, at a power factor between 0.0 and approximately 0.20, for a duration of 10 cycles
h. Nonwelding of Contacts: Rated for non-welding of contacts when used with the feeder overcurrent devices indicated and with the available fault current specified herein.
i. Main Contacts: Constructed of silver composition and protected by approved arcing contacts.
6.19 16262-4 394.107.001 SECTION 16262
AUTOMATIC TRANSFER SWITCHES
2.1.3.1 Auxiliary Contacts: Two normally open and two normally closed auxiliary contacts shall operate when the transfer switch is connected to the normal power source, and two normally open and two normally closed contacts shall operate when the transfer switch is connected to the emergency power source.
2.1.3.2 Supplemental Features: The ATS shall also be furnished with the following:
a. Service Entrance Rated ATS with 100% rated 400A circuit breaker.
b. Engine start contact.
c. Emergency power source monitor
d. Test switches.
e. Manual return-to-normal switch.
f. Motor starter control. Under-voltage and timing relays, including any auxiliary relays required, shall be installed in the ATS enclosure to provide an adequate number and type of properly rated contacts to control the operation of remote motor controllers or starters. Devices and wiring in and external to the ATS shall cause motors to be deenergized for an adjustable period of time before the operation of the ATS.
2.1.3.3 Operator: A manual operator, conforming to the applicable provisions of UL 1008, shall be provided to permit manual operation of the ATS under either loaded or no-load conditions.
2.1.3.4 Override Switch: The override switch shall bypass automatic transfer controls so the transfer switch will remain connected to the emergency power source, regardless of the conditions of the normal power source.
2.2 ENCLOSURE: The switch and accessories shall be in a wall-mounted and ventilated NEMA ICS 6, Type 12, smooth sheet metal enclosure constructed in accordance with UL 1008. Intake vent shall be screened and filtered. Exhaust vents shall be screened. Metal shall be not less than US Standard Gauge No. 14. Doors shall have hinges, locking handle latch, and gaskets at jamb, sill, and head. The enclosure shall be equipped with two grounding lugs grounding the enclosure. The Contractor's field wiring terminating within the enclosure shall comply with NFPA 70. If wiring is not color coded, wires shall be permanently tagged near the terminal at
6.19 16262-5 394.107.001 SECTION 16262
AUTOMATIC TRANSFER SWITCHES
each end with the wire number shown on approved shop drawings. Terminal blocks shall conform to NEMA ICS 4. Main switch terminals, including the neutral terminal, shall be of the pressure type and suitable for the termination of copper conductors shown.
2.2.1 Construction: The enclosure shall be constructed for convenient removal and replacement of contacts, coils, springs and control devices from the front without the removal of main power conductors or removal of major components.
2.2.2 Cleaning and Painting: Ferrous surfaces shall be cleaned and painted. Surfaces to be painted shall be free of all oil, grease, welding slag and spatter, mill scale, deleterious corrosion, dirt, and other foreign substances. Painting shall include at least one coat of rust-inhibiting primer and one coat of finish enamel. The rust-inhibiting primer shall be applied to a clean, dry surface as soon as practicable after cleaning. Painting shall be manufacturer's standard material and process, except the total dry film thickness shall be not less than 2.5 mils. Color of the finish coat may be the manufacturer's standard color, if approved, or No. 26314 Gray as specified in Fed. Std. 595. The finish shall be free from runs, sags, peeling or other defects.
PART 3 - EXECUTION
3.1 INSTALLATION: Installation shall conform to the requirements of NFPA 70 and manufacturer's recommendations.
3.2 FIELD TESTS AND INSPECTIONS: The Contractor shall furnish labor, equipment, and incidentals for, and shall perform all field tests. The Contractor shall give the Engineer 7 calendar days notice of the times scheduled for tests so that the Engineer may be present. Work affected by deficiencies shall be completely retested at the Contractor's expense. The manufacturer's factory representative shall assist the Contractor with the field test and inspection. Field tests shall include the following:
a. Simulate power failure and demonstrate complete ATS operation. Contractor shall show by demonstration in service that the ATS are in good operating condition, and function not less than five times.
b. Conduct 3-hour load run utilizing Contractor-furnished portable load banks with each power source as follows:
6.19 16262-6 394.107.001 SECTION 16262
AUTOMATIC TRANSFER SWITCHES
(1) 50% load: One hour (2) 75% load: One Hour (2) 100% load: Two hours
c. After 100% load bank tests are complete, Contractor shall perform complete system check in coordination with owners control equipment. Test(s) shall verify pump station and siderisers 12 and 13 will operate and run as required for worst case system load (i.e., number of pumps, staging, electric heat, etc.)
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - AUTOMATIC TRANSFER SWITCHES:
4.1.1 Measurement for Automatic Transfer Switches shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - AUTOMATIC TRANSFER SWITCHES:
4.2.1 For Automatic Transfer Switches, not included in other unit or lump sum price items, payment for Automatic Transfer Switches will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 16262-7 394.107.001 SECTION 16301
UNDERGROUND ELECTRICAL WORK – 600V & BELOW
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Underground Electrical Work – 600V & Below, as shown on the Plans, as specified, and/or directed.
1.1.2 For this Contract, all underground electrical work pertaining to the construction of the proposed 5kV medium voltage transformer feeder system shall also be as specified herein.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 Federal Specification (Fed. Spec.):
RR-F-621C Frame, Covers, Gratings, Steps, Sump and Catch Basin, Manhole
1.2.2 American Association of State Highway and Transportation Officials (AASHTO) Publications:
HB-12 Highway Bridges, Including Interim Specifications
M 198 Joints for Circular Concrete Sewer and Culvert Pipe Using Flexible Watertight Gaskets
1.2.3 American Concrete Institute (ACI) Publications:
315 Details and Detailing of Concrete Reinforcement
318 Building Code Requirements for Reinforced Concrete
1.2.4 American National Standards Institute (ANSI) Publication:
C2 National Electrical Safety Code (NESC)
6.19 16301-1 394.107.001 SECTION 16301
UNDERGROUND ELECTRICAL WORK – 600V & BELOW
1.2.5 American Society for Testing and Materials (ASTM) Publications:
B1 Hard-Drawn Copper Wire
B8 Concentric-Lay-Stranded Copper Conductors, Hard, Medium-Hard, or Soft
C32 Sewer and Manhole Brick (Made from Clay or Shale)
C260 Air-Entraining Admixtures for Concrete
C309 Liquid Membrane-Forming Compounds for Curing Concrete
D698 Moisture-Density Relations of Soils and Soil-Aggregate Mixtures Using 5.5-lb (2.49-kg) Rammer and 12-in. (305-mm) Drop
D1556 Density of Soil in Place by the Sand-Cone Method
D1557 Moisture-Density Relations of Soils and Soil-Aggregate Mixtures Using 10-lb (4.54-kg) Rammer and 18-in. (457-mm) Drop
D1682 Breaking Load and Elongation of Textile Fabrics
1.2.6 Association of Edison Illuminating Companies (AEIC) Publications:
1 Impregnated-Paper-Insulated Lead Covered Cable, Solid Type (10th Edition)
1.2.7 National Electrical Manufacturer's Association (NEMA) Publications:
RN 1 Polyvinyl-Chloride Externally Coated Galvanized Rigid Steel Conduit and Electrical Metallic Tubing
6.19 16301-2 394.107.001 SECTION 16301
UNDERGROUND ELECTRICAL WORK – 600V & BELOW
TC 2 Electrical Plastic Tubing (EPT) and Conduit (EPC-40 and EPC-80)
TC 3 PVC Fittings for Use With Rigid PVC Conduit and Tubing
TC 6 PVC and ABS Plastic Utilities Duct for Underground Installation
TC 9 Fittings for ABS and PVC Plastic Utilities Duct for Underground Installation
WC 7 Cross-Linked-Thermosetting- Polyethylene-Insulated Wire and Cable for the Transmission and Distribution of Electrical Energy (ICEA S-66-524)
WC 8 Ethylene-Propylene-Rubber-Insulated Wire and Cable for the Transmission and Distribution of Electrical Energy (ICEA S-68-516)
1.2.8 National Fire Protection Association (NFPA) Publication:
70 National Electrical Code (NEC)
1.2.9 U.S. Department of Agriculture, Rural Electrification Administration (REA) Bulletins:
344-2 List of Materials Acceptable for Use on Telephone Systems of REA Borrowers
345-6 Splicing Plastic-Insulated Cables (PC-2)
345-14 Direct Burial Telephone Cable (Air Core) (PE-23)
345-26 Buried Plant Housings (PE-35)
345-67 Filled Telephone Cables (PE-39)
6.19 16301-3 394.107.001 SECTION 16301
UNDERGROUND ELECTRICAL WORK – 600V & BELOW
1.2.10 Underwriters Laboratories Inc. (UL) Publications:
6 Rigid Metal Conduit
467 Grounding and Bonding Equipment
510 Insulating Tape
514A Metallic Outlet Boxes
514B Fittings for Conduit and Outlet Boxes
854 Service-Entrance Cables
1242-83 Intermediate Metal Conduit
1.3 GENERAL REQUIREMENTS: Section 16011, "Electrical General Requirements", applies to this Section with additions and modifications specified herein.
1.3.1 Laboratory Tests:
1.3.1.1 Determine soil-density relationships as specified for soil tests in Section 02200, "Excavation".
1.4 SUBMITTALS:
1.4.1 Submit on the following:
Conduit Insulating tape Hand hole frame and cover Cable lubricants Sealing material for precast manhole and hand hole joints Precast hand holes: Calculations and shop drawings for precast manholes and hand holes shall bear the seal of a registered professional engineer.
a. Material description (i.e., fc and fy) b. Manufacturer's printed assembly and installation instructions
6.19 16301-4 394.107.001 SECTION 16301
UNDERGROUND ELECTRICAL WORK – 600V & BELOW
c. Design calculations d. Reinforcing shop drawings prepared in accordance with ACI 315
1.4.2 Manufacturer's Instructions:
a. Manufacturer's directions for use of ground megger with proposed method indicated b. Terminator manufacturer's installation instructions
1.4.3 Certificates of Compliance:
1.4.3.1 Material and Equipment: Provide manufacturer's statement certifying that the product supplied meets or exceeds contract requirements.
a. Precast hand hole and accessories b. Hand hole frame and cover
PART 2 - PRODUCTS
2.1 MATERIALS AND EQUIPMENT: Provide materials and equipment listed by UL or approved by Factory Mutual (FM) System when such equipment is listed or approved.
2.1.1 Conduit: Shall be as shown on the contract drawings and as specified in Section 16132 “Conduit”.
2.1.2 Wire, cable and conductors:: Shall be as specified elsewhere.
2.1.2.1 Pull Wire: Shall be plastic, having a minimum tensile strength of 200 pounds.
2.1.2.2 Connectors and Terminals: Shall be designed and approved for use with the associated conductor material, and shall provide a uniform compression over the entire contact surface. Solderless terminal lugs shall be used on stranded conductors. For connecting aluminum to copper, connectors shall be the circumferentially compressed, metallurgically bonded type.
2.1.3 Grounding and Bonding Equipment: Shall be as specified in Section 16450 “Grounding”.
6.19 16301-5 394.107.001 SECTION 16301
UNDERGROUND ELECTRICAL WORK – 600V & BELOW
2.1.4 Materials for Hand Holes: Referred to throughout this Section as "structures" or "underground structure".
2.1.4.1 Metal Frames and Covers: Provide cast iron frames and covers conforming to Fed. Spec. RR-F-621 except where rolled steel floor plate is indicated.
PART 3 - EXECUTION
3.1 INSTALLATION: Underground installation shall conform to ANSI C2 and NFPA 70 except as otherwise specified or indicated.
3.1.1 Contractor Damage: The Contractor shall promptly repair any indicated utility lines or systems damaged by Contractor operations. Damage to lines or systems not indicated, which are caused by Contractor operations, shall be treated as "Changes" under the terms of the General Provisions of the Contract. If the Contractor is advised in writing of the location of a non- indicated line or system, such notice shall provide that portion of the line or system with "indicated" status in determining liability for damages. In any event, the Contractor shall immediately notify the Engineer of any such damage.
3.1.2 Underground Duct Without Concrete Encasement: Conduits shall be as specified in Section 16132 “Conduit”.
3.1.2.1 The top of the conduit shall be not less than indicated on contract drawings., shall have a minimum slope of 3 inches in each 100 feet away from buildings and toward handholes and other necessary drainage points, and shall run in straight lines except where a change of direction is necessary. As each conduit run is completed, a testing mandrel not less than 12 inches long with a diameter 1/4 inch less than the inside diameter of the conduit shall be drawn through each conduit, after which a stiff-bristled brush shall be drawn through until the conduit is clear of earth, sand, or gravel particles. Conduit plugs shall then immediately be installed. Ensure a minimum 3-inch clearance from the conduit to each side of the trench. Grade the bottom of the trenches smooth; where rock, soft spots, or sharp-edged materials are encountered, excavate the bottom for an additional 3 inches; fill with sand or earth, free from particles that would be retained on a 1/4-inch sieve; and tamp level with the original bottom.
3.1.3 Underground Duct With Concrete Encasement: Conduits shall be as specified in Section 16132 “Conduit”.
6.19 16301-6 394.107.001 SECTION 16301
UNDERGROUND ELECTRICAL WORK – 600V & BELOW
3.1.3.1 Shall be constructed of individual conduits encased in concrete. Except where rigid galvanized steel conduit is indicated or specified, the conduit shall conform to NEMA TC 6, Type EB. The type of conduit used shall not be mixed in any one duct bank. Ducts shall be a minimum of 4 inches in diameter unless otherwise indicated. The concrete encasement surrounding the bank shall be rectangular in cross-section and shall provide at least 3 inches of concrete cover around ducts. Separate conduit by a minimum concrete thickness of 3 inches,
3.1.3.2 The top of the concrete envelope shall be as indicated on Contract Drawings.
3.1.3.3 Duct banks shall have a continuous slope downward toward underground structures and away from buildings with a minimum pitch of 3 inches in 100 feet. Except at conduit risers, changes in direction of runs exceeding a total of 10 degrees, either vertical or horizontal, shall be accomplished by long sweep bends having a minimum radius of curvature of 25 feet; sweep bends may be composed of one or more curved or straight sections or combinations thereof. Manufactured bends shall have a minimum radius of 18 inches for use with conduits of less than 3 inches in diameter and a minimum radius of 36 inches for ducts of 3 inches in diameter and larger. Excavate trenches along straight lines from structure to structure before ducts are laid or structure constructed so the elevation can be adjusted, if necessary, to avoid unseen obstruction.
3.1.4 Conduit Duct Bank Construction:
3.1.4.1 Terminate conduits in end-bells where ducts enter underground structures. Stagger the joints of the conduits by rows and layers to strengthen the duct bank.
3.1.4.2 Provide plastic duct spacers that interlock vertically and horizontally. Provide for direct buried conduit duct banks as well as concrete encased duct banks. Spacer assembly shall consist of base spacers, intermediate spacers, and top spacers to provide a completely enclosed and locked-in duct bank. Install spacers per manufacturer's instructions, but provide a minimum of two spacer assemblies per 10 feet of duct bank. For concrete encased duct banks, before pouring concrete, anchor duct bank assemblies to prevent the assemblies from floating during concrete pouring. Anchoring shall be done by driving reinforcing rods adjacent to every other duct spacer assembly and attaching the rod to the spacer assembly.
3.1.4.3 As each section of a duct bank is completed from structure to structure, a testing mandrel not less than 12 inches long with a diameter 1/4 inch less than the inside diameter of the conduit shall be drawn through each conduit, after which a stiff-bristled brush, having the diameter of the conduit shall be drawn through until the conduit is clear of earth, sand, and gravel particles. Conduit plugs shall then be immediately installed.
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3.1.4.4 New conduit indicated as being unused or empty shall be provided with plugs on each end. Plugs shall contain a weep hole or screen to allow water drainage. Provide a plastic pull rope having 3 feet of slack at each end of unused or empty conduits.
3.1.4.5 Connections to Handholes: Duct bank envelopes connecting to underground structures shall be flared to have an enlarged cross-section at the manhole entrance to provide additional shear strength. The dimensions of the flared cross-section shall be larger than the corresponding manhole opening dimensions by no less than 12 inches in each direction. The perimeter of the duct bank opening in the underground structure shall be flared toward the inside or keyed to provide for a positive interlock between the duct bank and the wall of the structure. Vibrators shall be used when this portion of the envelope is poured to assure a seal between the envelope and the wall of the structure.
3.1.4.6 Connections to Existing Hand Holes: For duct bank connections to existing structures, break the structure wall out to the dimensions required and preserve the steel in the structure wall. Cut the steel and extend it into the duct bank envelope. Chip the perimeter surface of the duct bank opening to form a key or flared surface, providing a positive connection with the duct bank envelope.
3.1.4.7 Connections to Concrete Pads: For duct bank connections to concrete pads, break an opening in the pad out to the dimensions required and preserve the steel in the pad. Cut the steel and extend it into the duct bank envelope. Chip out the opening in the pad to form a key for the duct bank envelope.
3.1.4.8 Connections to Existing Ducts: Where connections to existing duct banks are indicated, excavate the banks to the maximum depth necessary. The banks shall be cut off and loose concrete removed from the conduits before new concrete-encased ducts are installed. A reinforced concrete collar, poured monolithically with the new duct bank, shall be provided to take the shear at the joint of the duct banks
3.1.4.9 Partially Completed Duct Banks: During construction wherever a construction joint is necessary in a duct bank, prevent debris such as mud, sand, and dirt from entering ducts by providing suitable conduit plugs. Fit concrete envelope of a partially completed duct bank with reinforcing steel extending a minimum of 2 feet back into the envelope and a minimum of 2 feet beyond the end of the envelope. Provide one No. 4 bar in each corner, 3 inches from the edge of the envelope. Secure corner bars with two No. 3 ties, spaced approximately 1 foot apart. Restrain reinforcing assembly from moving during concrete pouring.
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3.1.5 Concrete for Electrical Requirements: Concrete shall be 4000 psi minimum ultimate 28-day compressive strength with 1-inch maximum aggregate conforming to the requirements of Section 03300, "Cast-in-Place Concrete".
3.1.6 Buried Utility Warning and Identification Tape: Provide detectable aluminum foil plastic-backed tape or detectable magnetic plastic tape manufactured specifically for warning and identification of buried cable and conduit. Tape shall be detectable by an electronic detection instrument. Provide tape in rolls, 2 inches minimum width, color coded for the utility involved with warning and identification imprinted in bold black letters continuously and repeatedly over entire tape length. Warning and identification shall be CAUTION BURIED ELECTRIC CABLE BELOW or similar. Use permanent code and letter coloring unaffected by moisture and other substances contained in trench backfill material. Bury tape with the printed side up at a depth of 12 inches below the top surface of earth or the top surface of the subgrade under pavements.
3.1.7 Reconditioning of Surfaces:
3.1.7.1 Unpaved surfaces disturbed during the installation of duct shall be restored to the original elevation and condition. Sod or topsoil shall be preserved carefully and replaced after the backfilling is completed. Replace damaged sod with sod of equal quality. Where the surface is disturbed in a newly seeded area, the disturbed surface shall be reseeded with the same quantity and formula of seed as that used in the original seeding.
3.1.7.2 Paving Repairs: Where trenches, pits, or other excavations are made in existing roadways and other areas of pavement where surface treatment of any kind exists, such surface treatment or pavement shall be restored to the same thickness and in the same kind as previously existed, except as otherwise specified, and to match and tie into the adjacent and surrounding existing surfaces in a neat and acceptable manner.
3.1.8 Cable Pulling: Test existing ducts with a mandrel and thoroughly swab out to remove foreign material before the pulling of cables. Cables shall be pulled down grade with the feed-in point at the manhole or buildings of the highest elevation. Flexible cable feeds shall be used to convey cables through the manhole opening and into the ducts. Cable lubricants shall be lubricants specifically recommended by the cable manufacturer. Cable-pulling tensions shall not exceed the maximum pulling tension recommended by the cable manufacturer. Do not exceed the specified cable bending radii when installing cable under any conditions, including turn-ups into switches, transformers, switchgear, switchboards, and other enclosures. Cable with tape shield shall have a bending radius not less than 12 times the overall diameter of the completed
6.19 16301-9 394.107.001 SECTION 16301
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cable. Cable with wire shield shall have a bending radius not less than eight times the overall diameter of the completed cable. If basket-grip type cable-pulling devices are used to pull cable in place, cut off the section of cable under the grip before splicing and terminating.
3.1.8.1 Installation of Cables in Hand Holes and transformer pad/vaults: Route cables along walls providing the longest route and the maximum spare cable lengths. Form cables to closely parallel walls without interference to duct entrances. Support cables on brackets and cable insulators at a maximum of 4 feet. In existing hand hole, and vaults where new ducts are to be terminated, or where new cables are to be installed, the existing installation of cables, cable supports, and grounding shall be modified as required with cables arranged and supported as specified for new cables. Identify each cable by corrosion-resistant embossed metal tags attached in each underground structure in accordance with the cable schedule and as approved by the Engineer. Example: 600V cable, Circuit 4-Sub. NB - to SP. Identify each phase of the 600V cable.
3.1.8.2 In all underground structures (hand holes and transformer pad/vaults), feeder conductors shall completely encircle the structure a minimum of two times to all for spare length of conductor.
3.1.9 Hand Holes:
3.1.9.1 Workmanship: Underground structures shall be poured in place or may be of precast construction as specified herein. Horizontal concrete surfaces of floors shall have a smooth trowel finish. Cure concrete by applying two coats of white pigmented membrane forming-curing compound in strict accordance with the manufacturer's printed instructions, except that precast concrete may be steam cured. Curing compound shall conform to ASTM C309. Locate duct entrances and windows in the center of end walls (shorter) and near the corners of sidewalls (longer) to facilitate cable racking and splicing. Covers for underground structures shall fit the frames without undue play. Steel and iron shall be formed to shape and size with sharp lines and angles. Castings shall be free from warp and blowholes that may impair strength or appearance. Exposed metal shall have a smooth finish and sharp lines and arrises. Provide necessary lugs, rabbets, and brackets. Set pulling-in irons and other built-in items in place before depositing concrete. The words "electric" or similar" shall be cast in the top face of manhole covers.
3.1.9.2 Optional Precast Concrete Construction: In lieu of poured-in-place concrete hand holes, the Contractor may, at his option, provide precast concrete structures, subject to the requirements specified below. Precast units shall be the product of a manufacturer regularly
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engaged in the manufacture of precast concrete products, including precast manholes and hand holes.
a. General: Precast concrete structures shall have the same accessories and facilities as required for poured-in-place structures. Likewise, precast structures shall have plan area and clear heights not less than those of poured-in-place structures. Concrete materials and methods of construction shall be the same as for poured-in-place concrete construction, as modified herein. Slope in floor may be omitted provided precast sections are poured in reinforced steel forms. Concrete for precast work shall have an ultimate 28-day compressive strength of not less than 4000 psi. Structures may be precast to the design and details indicated for poured-in-place construction, precast monolithically and placed as a unit, or structures may be assembled sections, designed and produced by the manufacturer in accordance with the requirements specified. Structures shall be identified with the manufacturer's name embedded in, or otherwise permanently attached to, an interior wall face.
b. Design for Precast Structures: ACI 318. In the absence of detailed on-site soil information, design for the following soil parameters/site conditions:
Angle of Internal Friction (0) = 30 degrees
Unit Weight of Soil ( ) = 110 pcf
Coefficient of Lateral Earth Pressure (Ko) = 0.50
Ground Water Level = 3 feet below ground elevation
Vertical design loads shall include full dead, superimposed dead, and live loads including a 30 percent magnification factor for impact. Live loads shall consider all types and magnitudes of vehicular (automotive, industrial, or aircraft) traffic to be encountered. The minimum design vertical load shall be for H20 highway loading per AASHTO HB-12.
Horizontal design loads shall include full geostatic and hydrostatic pressures for the soil parameters, water table, and depth of installation to be encountered. Also, horizontal loads imposed by adjacent structure foundations, and horizontal load components of vertical design loads, including impact, shall be considered, along with a pulling-in iron design load of 6000 pounds.
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Each structural component shall be designed for the load combination and positioning resulting in the maximum shear and moment for that particular component.
Design shall also consider the live loads induced in the handling, installation, and backfilling of the manholes. Provide lifting devices to ensure structural integrity during handling and installation.
c. Construction: Structure top, bottom, and walls shall be of a uniform thickness of not less than 6 inches. Thin-walled knock-out panels for designed or future duct bank entrances shall not be permitted. Quantity, size, and location of duct bank entrance windows shall be as directed, and cast completely open by the precaster. The size of the windows shall exceed the nominal duct bank envelope dimensions by at least 12 inches in each direction to preclude in-field window modifications made necessary by duct bank misalignment. However, the sides of precast windows shall be a minimum of 6 inches from the inside surface of adjacent walls, floors, or ceilings. Form the perimeter of precast window openings to have a keyed or inward flared surface to provide a positive interlock with the mating duct bank envelope. Provide welded wire fabric reinforcing through window openings for in-field cutting and flaring into duct bank envelopes. Provide additional reinforcing steel comprised of at least two No. 4 bars around window openings. The minimum concrete cover for reinforcing steel shall be 2 inches. Provide drain sumps for precast structures a minimum of 12 inches in diameter and 4 inches deep.
d. Joints: Provide tongue-and-groove joints on mating edges of precast components. Shiplap joints shall not be allowed. Design joints to firmly interlock adjoining components and to provide waterproof junctions and adequate shear transfer. Seal joints watertight using preformed plastic strip conforming to AASHTO M 198, Type B. Install sealing material in strict accordance with the sealant manufacturer's printed instructions. Provide waterproofing at conduit/duct entrances into structures and, where access frame meets the top slab, provide continuous grout seal.
3.1.9.3 Metal Frames and Covers: Frames and covers of steel shall be welded by qualified welders in accordance with standard commercial practice. Steel covers shall be rolled-steel floor plate having an approved anti-slip surface. Hinges shall be of wrought steel, 5 by 5 inches by approximately 3/16 inch thick, without screw holes, and shall be for full surface application by fillet welding. Hinges shall have non-removable pins and five knuckles. The surfaces of plates under hinges shall be true after the removal, by grinding or other approved method, of raised lugs.
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3.1.9.4 Precast Hand Holes Installation: Commercial precast assembly shall be set on minimum of 6 inches of level, 90 percent compacted granular fill, 3/4 inch to 1 inch size, extending 12 inches beyond the hand hole on each side. Granular fill shall be compacted by a minimum of four passes with a plate type vibrator. Installation shall conform to the manufacturer's instructions.
3.1.9.5 Field Painting: Cast-iron frames, covers, and gratings not buried in masonry shall be cleaned of mortar, rust, grease, dirt, and other deleterious materials, and coated with bituminous paint. Steel frames not buried in masonry and steel covers shall be cleaned of mortar, dirt, and grease by an approved blasting process. Surfaces that cannot be cleaned satisfactorily by blasting shall be cleaned to bare metal by wire brushing or other mechanical means. Surfaces contaminated with rust, dirt, oil, grease, or other contaminants shall be washed with solvents until thoroughly cleaned. Immediately after cleaning, surfaces shall be coated with a pretreatment coating or a crystalline phosphate coating. As soon as practicable after the pretreatment coating has dried, treated surfaces shall be coated with zinc chromate primer and synthetic exterior gloss enamel.
3.1.10 Excavating, Backfilling, and Compacting: Provide under this Section as specified in Section 02220, "Excavation".
3.1.11 Cable Terminating: Protect terminations of insulated power and lighting cables from accidental contact, deterioration of coverings, and moisture by the use of terminating devices and materials. Make terminations by using materials and methods indicated or specified herein or as designated by the written instruction of the cable manufacturer and termination kit manufacturer. Adequately support cables and cable terminations to avoid any excessive strain on the termination and the conductor connection.
3.1.12 Splices for 600-Volt Class Cables: Splices in underground systems duct shall be made only in accessible locations such as hand holes, using a compression connector on the conductor and by insulating and waterproofing by one of the following methods suitable for continuous submersion in water.
3.1.12.1 Cast-type splice insulation shall be provided by means of a molded casting process employing a thermosetting epoxy resin insulating material which shall be applied by a gravity-poured method or by a pressure-injected method. The component materials of the resin insulation shall be in a packaged form ready for convenient mixing without removing from the package. Do not allow the cables to be moved until after the splicing material has completely set.
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3.1.12.2 Gravity-poured method shall employ materials and equipment contained in an approved commercial splicing kit which includes a mold suitable for the cables to be spliced. When the mold is in place around the joined conductors, prepare and pour the resin mix into the mold. Do not allow cables to be moved until after the splicing materials have completely set.
3.1.13 Grounding: Noncurrent-carrying metallic parts associated with electrical equipment shall have a maximum resistance to solid earth ground not exceeding the following values:
3.1.13.1 Grounding electrodes shall be cone-pointed ground rods, driven full depth plus 6 inches, installed when indicated to provide an earth ground of the appropriate value for the equipment being grounded.
3.1.13.2 Grounding connections which are buried or otherwise normally inaccessible, and excepting specifically those connections for which access for periodic testing is required, shall be made by exothermic weld or compression connector. Exothermic welds shall be made strictly in accordance with the weld manufacturer's written recommendations. Welds which are "puffed up" or which show convex surfaces, indicating improper cleaning, are not acceptable. Mechanical connectors are not required at exothermic weldments. Compression connector shall be the type which uses a hydraulic compression tool to provide the correct circumferential pressure. Tools and dies shall be as recommended by the manufacturer. An embossing die code or other standard method shall provide visible indication that a connector has been adequately compressed on the ground wire.
3.1.13.3 Grounding conductors shall be stranded-bare copper conforming to ASTM B8, Class B, for sizes No. 6 AWG and larger, and shall be solid-bare copper conforming to ASTM B1 for sizes No. 8 and smaller. Cable sheaths, cable shields, conduit, and equipment shall be grounded with No. 6 AWG.
3.1.13.4 Ground Cable Crossing Expansion Joints: Protect ground cables crossing expansion joints or similar separations in structures and pavements by use of approved devices or methods of installation which provide the necessary slack in the cable across the joint to permit movement. Use stranded or other approved flexible copper cable run or jumper across such separations.
3.1.14 Special Conditions: During the construction of duct banks and underground structures located in access roads, the access roads shall remain open to traffic. Plan and execute the work to meet this condition.
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3.2 FIELD TESTS: As an exception to requirements that may be stated elsewhere in the Contract, notify the Owners Designated Representative in writing at least 2 weeks prior to each test. Furnish labor, equipment, and incidentals required for testing. Correct defects in the work provided by the Contractor and repeat tests until the work is in compliance with Contract requirements. Show by demonstration in service that circuits and devices are in good operating condition. Tests shall be such that each item of control equipment will function not less than five times.
3.2.1 Conductors: Required testing is specified in sections pertaining to those conductors.
3.2.2 Ground Rods: Test ground rods for ground resistance value before any wire is connected. Perform ground resistance measurements in normally dry weather, not less than 48 hours after rainfall. Ground resistance shall also be measured for each piece of equipment to the ground electrode. Use a portable ground testing megger to test each ground or group of grounds. The instrument shall be equipped with a meter reading directly in ohms or fractions thereof to indicate the ground value of the ground electrode under test. Provide one copy of the ground megger manufacturer's directions, indicating the method to be used.
3.2.3 Compaction: Backfill shall be tested in accordance with other Section 02220 “Excavation”.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - UNDERGROUND ELECTRICAL WORK – 600V & BELOW:
4.1.1 Measurement for Underground Electrical Work – 600V & Below shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - UNDERGROUND ELECTRICAL WORK – 600V & BELOW:
4.2.1 For Underground Electrical Work – 600V & Below, not included in other unit or lump sum price items, payment for Underground Electrical Work – 600V & Below will be made at the applicable price stated in the Bid.
END OF SECTION
6.19 16301-15 394.107.001 SECTION 16321
INTERIOR TRANSFORMERS
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Interior Transformers, as shown on the Plans, as specified, and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American National Standards Institute, Inc. (ANSI) Publications:
C57.12.00 General Requirements for Liquid-Immersed Distribution, Power, and Regulating Transformers
C57.12.01 General Requirements for Dry-Type Distribution and Power Transformers
C57.12.90 Test Code for Liquid-Immersed Distribution, Power, and Regulating Transformers and Guide for Short-Circuit Testing of Distribution and Power Transformers
C57.12.91 Test Code for Dry-Type Distribution and Power Transformers
C57.94 Recommended Practice for Installation, Application, Operation, and Maintenance of Dry-Type General Purpose Distribution and Power Transformers
Z35.1 Accident Prevention Signs
1.2.2 American Society For Testing and Materials (ASTM) Publications:
D92 Flash and Fire Points by Cleveland Open Cup
D117 Electrical Insulating Oils of Petroleum Origin
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D877 Dielectric Breakdown Voltage of Insulating Liquids Using Disk Electrodes
D3487 Mineral Insulating Oil Used in Electrical Apparatus
1.2.3 Factory Mutual Engineering and Research Corporation (FM) Publication:
P7825 Approval Guide
1.2.4 National Electrical Manufacturers' Association (NEMA) Publications:
NEMA ICS6 Enclosures for Industrial Controls and Systems
TR1 Transformers, Regulators and Reactors
1.2.5 National Fire Protection Association (NFPA) Publications:
NFPA 70 National Electrical Code
70B Electrical Equipment Maintenance
1.2.6 Underwriters Laboratories, Inc. (UL) Publication:
UL 467 Grounding and Bonding Equipment
1.3 GENERAL REQUIREMENTS: Section 16011, "Electrical General Requirements", applies to this section, with the additions and modifications specified herein.
1.4 DESCRIPTION OF WORK: The work includes providing new transformers for indoor use.
1.5 SUBMITTALS:
1.5.1 Detail Drawings: Shop Drawings: Shop drawings for dry-type transformers shall indicate, but shall not be limited to, the following:
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a. Overall dimensions b. Impedance value c. Tap ratings
1.5.2 Test Reports:
a. Transformer Tests: ANSI C57.12.91, as applicable, including the following:
(1) Routine Tests: Performed by the manufacturer on each transformer to ensure that design performance is maintained in production.
(2) Design Tests: Test reports will be accepted as proof of compliance with design test requirements.
1.5.3 Operation and Maintenance Manuals:
a. Dry-type transformers
PART 2 - PRODUCTS
2.1 TRANSFORMERS: The kVA rating shall be conspicuously displayed on each transformer enclosure.
2.1.1 Dry-Type: Two-winding type, 60 Hz, 150 degrees C rise above 40 degrees C maximum ambient in a NEMA 1 for indoor, NEMA 3R for outdoor enclosure as defined in NEMA ICS6. Transformer windings shall be vacuum cast in fiberglass-reinforced resin.
2.1.1.1 Transformer shall be self-cooled Class AA.
2.1.1.2 Insulation system shall allow transformer to have a minimum overload capacity of 10 percent at rated voltage without exceeding specified winding temperature rise above 40 degrees C maximum ambient. Accessories shall include grounding straps, lifting lugs, and diagrammatic nameplate. Transformer base shall be constructed to permit skidding or rolling in any direction. Transformer shall have an insulated low-voltage neutral bushing with removable ground strap in both primary and secondary compartments with lugs for ground cable.
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2.1.1.3 Taps (Deenergized Operation): Taps shall allow transformers to deliver rated kVA at any tap setting. Transformer shall have four taps: (two 2 1/2-percent full capacity above and two 2 1/2-percent full capacity below rated primary voltage).
2.1.1.4 Sound Level: Shall be an average of 3 dB lower than NEMA TR1 standard sound levels for the transformer size indicated
2.1.2 Transformers shall be DOE certified.
2.1.3 Transformers shall have copper primary and secondary windings
PART 3 - EXECUTION
3.1 INSTALLATION: NFPA 70, and to the requirements specified herein.
3.2 Install interior and exterior dry type transformers per manufacturer’s written instructions.
3.3 GROUNDING AND BONDING EQUIPMENT: UL 467, except as indicated or specified otherwise.
3.4 FIELD TESTS AND INSPECTIONS:
3.4.1 Acceptance Checks and Tests: Perform in accordance with the manufacturer's recommendations. Perform work in a careful and safe manner so as not to endanger personnel or equipment. Acceptance checks and test shall include, but not be limited to, the following:
a. Inspect devices, equipment, etc. for damage or maladjustment caused by shipment or installation.
b. Remove wedges, ties, and blocks installed by the manufacturer to prevent damage during shipment.
c. Verify minimum resistance to ground of grounding lugs and grounding connections.
3.4.2 Transformer Test: Test transformer secondary voltages and adjust the primary voltage at the transformer to provide a secondary voltage of nameplate rated secondary voltage.
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3.4.3 Final Testing: Upon completion of acceptance checks and tests, show by demonstration in service that transformers and devices are in good operating condition and properly performing the intended function. As an exception to requirements that may be stated elsewhere in the contract, the Engineer shall be given 5 working days advance notice of the dates and times for checks, settings, and tests.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - INTERIOR TRANSFORMERS:
4.1.1 Measurement for Interior Transformers shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - INTERIOR TRANSFORMERS:
4.2.1 For Interior Transformers, not included in other unit or lump sum price items, payment for Interior Transformers will be made at the applicable price stated in the Bid.
END OF SECTION
4.19 16321-5 394.107.001 SECTION 16441
PANELBOARDS
PART 1 – GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials, equipment and accessories for Panelboards, as shown on the Plans, as specified and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only and shall be the most current version.
1.2.1 National Electrical Contractors Association (NECA) Publication:
Standard of Installation
1.2.2 National Electrical Manufacturers Association (NEMA) Publications:
AB1 Molded Case Circuit Breakers
PB 1 Panelboards
PB 1.1 Instructions for Safe Installation, Operation and Maintenance of Panelboards Rated 600 Volts or Less
1.2.3 National Fire Protection Association (NFPA) Publication:
70 National Electrical Code
1.3 SUBMITTALS:
1.3.1 Submittal Packages: Submit the shop drawings, product data, and the quality control submittals specified below at the same time as a package.
1.3.2 Shop Drawings: Include the following for each panelboard.
1.3.2.1 Cabinet and gutter size.
1.3.2.2 Voltage and current rating.
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1.3.2.3 Panelboard short circuit rating. Indicate if rating is Fully Rated Equipment Rating, or where acceptable, UL listed Integrated Equipment Short Circuit Rating.
1.3.2.4 Circuit Breaker Enumeration (Frame, Poles, KAIC.): Indicate if circuit breakers are suitable for the panelboards’ Fully Rated Equipment Rating, or where acceptable, are series connected devices that have been test verified and listed with UL (include documentation proving the compatibility of the proposed circuit breaker combinations). Circuit breakers do not have to be listed as series connected devices when all of the circuit breaker interrupting ratings are equal to, or greater than, the short circuit rating of the panelboard.
1.3.2.5 Accessories.
1.3.3 Product Data:
1.3.3.1 Catalog sheets, specifications and installation instructions.
1.3.3.2 Bill of materials.
1.3.4 Maintenance Data: Include spare parts listing; source and current prices of replacement parts and supplies; and recommended maintenance procedures and intervals.
1.3.5 Contract Closeout Submittals:
1.3.5.1 Operation and Maintenance Data: Deliver 2 copies, covering the installed products, to Owner.
PART 2 – PRODUCTS
2.1 PANELBOARDS:
2.1.1 As produced by Cutler-Hammer/Eaton Corp, General Electric Co., Siemens/ITE, or Square D Co., having:
2.1.1.1 Flush or surface type cabinets as indicated on the Contract Drawings.
2.1.1.2 Increased gutter space for gutter taps, sub-feed wiring, through-feed wiring, oversize lugs.
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2.1.1.3 UL label “SUITABLE FOR USE AS SERVICE EQUIPMENT” where used as service equipment.
2.1.1.4 Door and one piece trim. Door fastened to trim with butt or piano hinges. Trim fastened to cabinet with devices having provision for trim adjustment. Provide door-in-door trim.
2.1.1.5 Door lock. 2 keys with each lock. All locks shall be keyed alike.
2.1.1.6 Solid copper bus bars. Ampere rating of bus bars not less than frame size of main circuit breaker.
2.1.1.7 Full capacity copper isolated neutral bus in panelboards where neutrals are required and the panel is not utilized as service equipment.
2.1.1.8 Copper equipment grounding bus in panelboards where equipment grounding conductors are required.
2.1.1.9 Sections designated “space” or “provision for future breaker” equipped to accept future circuit breakers.
2.1.1.10 Lock on devices for exit light, fire alarm, stair well circuits or as indicated on Contract Drawings.
2.1.1.11 Provisions for padlocking circuit breaker handle in OFF position where indicated.
2.1.1.12 Blank circuit directories in plastic pockets.
2.1.1.13 Short circuit rating not less than indicated on panelboard schedule. Furnish panelboards having Fully Rated Equipment Rating (the short circuit rating of the panelboard is equal to the lowest interrupting rating of any device installed in the panelboard).
2.1.1.14 Molded Case Circuit Breakers.
2.1.1.14.1 Molded Case Circuit Breakers: NEMA AB 1, bolt-on type thermal magnetic trip circuit breakers, with common trip handle for all poles. Do not use tandem circuit breakers. Type HACR for air conditioning equipment circuits, Class A ground fault interrupter circuit breakers where scheduled. The fault interrupter shall detect and trip on current imbalance of 30 milliamperes or greater per requirements of UL 943 for Class B GFCI devices.
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2.1.1.14.2 Components: See panelboard schedule for specific components required for each circuit breaker. In addition to the specific components, equip each circuit breaker with additional components as required to achieve a coordinated selective scheme between the main circuit breaker and the branch/feeder circuit breakers when indicated on the panelboard schedule that a coordinated selective scheme is required.
2.1.1.14.3 Single pole 15 amp and 20 amp circuit breakers marked SWD where used as switches.
2.1.1.14.4 Single pole and two pole 15, 20, and 30 amp circuit breakers rated for high intensity discharge lighting loads when applicable.
2.1.1.15 Size of circuit breakers and rating of main lugs shall be as indicated on Contract Drawings.
2.1.1.16 Enclosure: NEMA 12.
2.1.1.17 Equip panelboards with secondary surge arresters; GE’s Tranquell Series, Joslyn’s Mfr. Co.’s Surge Tec Series, Intermatic Incorp.’s AG2401 or AG6503, Square D Co.’s SDSA 1175 or SDSA 3650, to suit system primary (transformer size, available current) and secondary characteristics.
2.2 NAMEPLATES:
2.2.1 General: Precision engrave letters and numbers with uniform margins, character size minimum 3/16 inch high.
2.2.1.1 Phenolic: Two color laminated engravers stock, 1/16 inch minimum thickness, machine engraved to expose inner core color (white).
2.2.1.2 Aluminum: Standard aluminum alloy plate stock, minimum .032 inches thick, engraved areas enamel filled or background enameled with natural aluminum engraved characters.
2.2.1.3 Materials for Outdoor Applications: As recommended by nameplate manufacturer to suit environmental conditions.
4.19 16441-4 394.107.001 SECTION 16441
PANELBOARDS
PART 3 – EXECUTION
3.1 INSTALLATION:
3.1.1 Install panelboards in accordance with NEMA Publication No. PB1.1 “General Instructions for Proper Installation, Operation and Maintenance of Panelboards Rated 600 Volts or Less”.
3.1.2 Flush Cabinets: Set flush cabinets so that edges will be flush with the finished wall line. Where space will not permit flush type cabinets to be set entirely in the wall, set cabinet as nearly flush as possible, and cover the protruding sides with the trim extending over the exposed sides of the cabinet and back to the finished wall line.
3.1.3 Directory: Indicate on typewritten directory the equipment controlled by each circuit breaker, and size of feeder servicing panelboard. For power panelboards also include ATE rating and feeder size for each breaker.
3.1.4 Identification:
3.1.4.1 Use nameplates, or stencil on front of each panelboard with white paint, “LP-1, PP-1, etc.” in 1/2 inch lettering corresponding to panelboard designations on the drawings, and electrical parameters (phase, wire, voltage).
3.1.4.2 Install a nameplate on each panelboard that explains the means of identifying each ungrounded system conductor by phase and system. Examples of nameplate statements:
3.1.4.2.1 Identification of 120/208 and 120/240 Volt Circuit Conductors:
a. 2 wire circuit - white*, black. b. 3 wire circuit - white*, black, red (also for 120/240V, single phase systems) c. 4 wire circuit - white*, black, red, blue.
*White is used only as neutral. Where neutral is not required, black, red, or black, red, blue is used for phase to phase circuits.
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3.1.4.2.2 Identification of 277/480 Volt Circuit Conductors:
a. 2 wire circuit - natural gray**, brown. b. 3 wire circuit - natural gray**, brown, yellow. c. 4 wire circuit - natural gray**, brown, yellow, orange.
**Natural gray is used only as neutral. Where neutral is not required, brown, yellow, or brown, yellow, orange is used for phase to phase circuits.
3.1.5 Height: 6 feet to top of panelboard; install panelboards taller than 6 feet with bottom no more than 4 inches above floor.
3.1.6 Provide filler plates for unused spaces in panelboards.
3.1.7 Provide typed circuit directory for each branch circuit panelboard. Revise directory to reflect circuiting changes required to balance phase loads.
3.1.8 Provide spare conduits out of each recessed panelboard to an accessible location above accessible ceiling. Minimum spare conduits: 5 empty1 inch. Identify each as SPARE.
3.1.9 Ground and bond panelboard enclosure according to Section 16450.
3.2 FIELD QUALITY CONTROL:
3.2.1 System Acceptance Test:
3.2.1.1 Preparation: Notify Owner/Engineer at least 3 working days prior to the test so arrangements can be made prior to the test to have a Facility Representative witness the test.
3.2.1.2 Make the following tests:
3.2.1.2.1 Test circuit breakers that have ground fault protection.
3.2.1.2.2 Test programmable solid state trip devices in accordance with the manufacturer’s recommendations.
3.2.1.2.3 Supply all equipment necessary for system adjustment and testing.
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PANELBOARDS
3.2.1.2.4 Measure steady state load currents at each panelboard feeder; rearrange circuits in the panelboard to balance the phase loads to within 20 percent of each other. Maintain proper phasing for multi-wire branch circuits.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT – PANELBOARDS:
4.1.1 Measurement for Panelboards shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT – PANELBOARDS:
4.2.1 For Panelboards, not included in other unit or lump sum price items, payment for Panelboards will be made at the applicable price stated in the Bid.
END OF SECTION
4.19 16441-7 394.107.001 SECTION 16450
GROUNDING
PART 1 - GENERAL
1.1 DESCRIPTION: Under this Section, the Contractor shall furnish all labor, materials and equipment for Grounding and bonding of electrical installations as shown on the Plans, as specified and/or directed.
1.1.1 Existing site conditions may necessitate use of alternative grounding systems to achieve required ohm values. Existing site conditions are to include minimum soil cover over bedrock and exposed bedrock.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American National Standards Institute (ANSI), Electronic Industries Alliance (EIA), Telecommunications Industry Association (TIA) Publication: (ANSI/EIA/TIA)
607 Commercial Building Grounding and Bonding Requirements for Telecommunications
1.2.2 Institute of Electrical and Electronics Engineers (IEEE) Publications:
81 Guide for Measuring Earth Receptivity, Ground Impedance and Earth Surface Potential of a Ground System
142 Recommended Practice for Grounding of Industrial and Commercial Power Systems
1100 Recommended Practice for Powering and Grounding Sensitive Electronic Equipment
1.2.3 National Fire Protection Association (NFPA) Publication:
70 National Electrical Code (NEC)
1.2.4 Underwriters Laboratories, Inc. (UL) Publications:
83 Thermoplastic-Insulated Wires and Cables 44 Rubber-Insulated Wires and Cables 467 Grounding and Bonding Equipment
4.19 16450-1 394.107.001 SECTION 16450
GROUNDING
1.3 RELATED SECTIONS:
1.3.1 Section 16011, “Electrical General Requirements”.
1.4 SUBMITTALS:
1.4.1 Submit the following:
1.4.2 Submit test reports in accordance with Section 16011, “Electrical General Requirements”.
1.4.2.1 Certified test reports of ground resistance.
1.4.2.2 Certifications: Two weeks prior to final inspection, deliver to the Owner’s designated representative four copies of the certification that the material and installation is in accordance with the drawings and specifications and has been properly installed.
PART 2 – PRODUCTS
2.1 GROUNDING WIRES:
2.1.1 General Purpose: UL and NEC approved types, copper, with TW, THW, XHHW or dual rated THHN-THWN insulation color identified green.
2.1.2 Isolated Power System: Type XHHW insulation with a dielectric constant of 3.5 or less.
2.1.3 Size wire not less than what is shown and not less than required by the NEC.
2.1.4 Stranded bare copper ground conductor where indicated on drawings.
2.2 GROUND RODS:
2.2.1 Copper clad steel, 3/4-inch diameter by l0 feet long.
4.19 16450-2 394.107.001 SECTION 16450
GROUNDING
PART 3 - EXECUTION
3.1 INSTALLATION:
3.1.1 Ground as shown and as hereinafter specified in accordance with the NEC.
3.1.2 System Grounding:
3.1.2.1 Ground the electrical service system neutral at service entrance equipment to grounding electrodes. Concrete encased electrodes shall be connected as the most effective grounding electrodes. Provide a completely grounded system in accordance with Article 250 of the NEC.
3.1.2.2 Ground each separately-derived system neutral to separate grounding electrode system. Transformer, UPS systems, power conditioners, inverters, or other power supplies are separately derived systems. Standby or emergency generators are separately derived systems if the neutral is bonded to the generator frame and if there is no direct connection of the generator neutral conductor to the service neutral conductor.
3.1.2.3 Provide communications system grounding conductor connected to separate electrode (ground bus) that is shall be installed in each IT room. Bond together system neutrals, service equipment enclosures, exposed non-current carrying metal parts of electrical equipment, metal raceway systems, cable trays, auxiliary gutters, meter fittings, boxes, cable armor, cable sheath, ground bus in electrical rooms and IT rooms, metal frame of the building or structure, ground ring, lightning down lead conductor, grounding conductor in raceways and cables, receptacle ground connectors, and metal underground water pipe. Bonding jumpers shall be installed around non-metal fittings or insulating joints to ensure electrical continuity. Bonding shall be provided where necessary to ensure electrical continuity and the capacity to conduct safely any fault current likely to be imposed.
3.1.2.4 Secondary service neutrals ground at the supply side of the secondary disconnecting means and at the related transformers.
3.1.2.5 Separately derived systems (transformers downstream from the service entrance) ground the secondary neutral.
3.1.2.6 Isolation transformers and isolated power systems shall not be system grounded.
3.1.3 Equipment Grounding:
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3.1.3.1 Metallic structures, enclosures, raceways, junction boxes, outlet boxes, cabinets, machine frames, and other conductive items in close proximity with electrical circuits shall be grounded for personnel safety and to provide a low impedance path for possible ground fault currents.
3.2 PRIMARY EQUIPMENT AND CIRCUITS:
3.2.1 Switchgear: Provide a bare grounding electrode conductor from the switchgear ground bus to a grounding electrode system, metal underground water pipe and driven ground rods for the grounding electrode. Where a new foundation/footer is constructed for a building/structure the grounding electrode system shall also be bonded to the concrete-encased electrode (reinforcing steel in foundation/footer). Coordinate with General Contractor.
3.2.2 Duct Banks and Manholes:
3.2.2.1 Provide a bare equipment grounding conductor in each duct bank containing medium or high voltage cables. Connect the grounding conductors to the switchgear ground bus, to all manhole hardware, to the cable shielding of medium or high voltage cable splices and terminations, and equipment enclosures.
3.2.2.2 Provide a grounding conductor having at least 50 percent ampacity of the largest phase conductor in the duct bank.
3.2.2.3 Connect the equipment grounding conductor to the ground rod.
3.2.3 Outdoor Fences: Connect outdoor fences around electrical equipment to the grounding electrode system.
3.2.4 Metallic Conduit: Metallic conduits which terminate without mechanical connection to a housing of electrical equipment by means of locknut and bushings or adapters, provided with grounding bushings. Connect bushings with a bare grounding conductor to the equipment ground bus.
3.2.5 Lightning Arresters: Connect lightning arrester grounds to the equipment ground bus, or ground rods as applicable.
4.19 16450-4 394.107.001 SECTION 16450
GROUNDING
3.3 SECONDARY EQUIPMENT AND CIRCUITS:
3.3.1 Main Bonding Jumper: Connect the secondary service neutral to the ground bus in the service equipment.
3.3.2 Water Pipe and Supplemental Electrode:
3.3.2.1 Provide a ground conductor connection between the service equipment ground bus and the metallic water pipe system. Jumper insulating joints/meter in the water pipe.
3.3.2.2 Provide a supplemental ground electrode and bond to the water pipe ground, or connect to the service equipment ground bus.
3.3.2.3 Where a new foundation/footer is constructed for a building/structure, the grounding electrode system shall also be bonded to the concrete-encased electrode (reinforcing steel in foundation/ footer). Coordinate with General Contractor.
3.3.3 Service Disconnect (Separate Individual Enclosure): Provide a ground bar bolted to the enclosure with lugs for connecting the various grounding conductors.
3.3.4 Switchgear and Switchboards:
3.3.4.1 Connect the various feeder green grounding conductors to the ground bus in the enclosure with suitable pressure connectors.
3.3.4.2 Connect the grounding electrode conductor to the ground bus.
3.3.4.3 Connect the neutral to the ground bus (main bonding jumper).
3.3.4.4 Connect metallic conduits, which terminate without mechanical connection to the housing, by grounding bushings and ground wire to the ground bus.
3.3.5 Conduit Systems:
3.3.5.1 Ground all metallic conduit systems.
3.3.5.2 Non-metallic conduit systems shall contain a grounding conductor.
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GROUNDING
3.3.5.3 Conduit provided for mechanical protection containing only a grounding conductor, bond to that conductor at the entrance and exit from the conduit.
3.3.6 Feeders and Branch Circuits: Install green grounding conductors with feeders and branch circuits as follows:
a. Feeders. b. Branch Circuits. c. Receptacle Outlets. d. Directly Connected Equipment, Appliances and Devices. e. Motors and Motor Controllers. f. Fixed Equipment and Appurtenances. g. Items of equipment where the final connection is made with flexible metal conduit shall have a grounding wire. h. Additional locations and systems as shown.
3.3.7 Boxes, Cabinets, Enclosures and Panelboards:
3.3.7.1 Bond the grounding wires to each pull box, junction box, outlet box, cabinets, and other enclosures through which the ground wires pass.
3.3.7.2 Provide lugs in each box and enclosure for ground wire termination.
3.3.7.3 Provide ground bars in panelboards, bolted to the housing, with sufficient lugs for terminating the ground wires.
3.3.8 Motors and Starters:
3.3.8.1 Provide lugs in motor terminal box and starter housing for ground wire termination.
3.3.8.2 Make ground wire connections to ground bus in motor control centers.
3.3.9 Receptacles are not approved for grounding through their mounting screws. Ground with a ground wire from green ground terminal on the receptacle to the outlet box ground screw.
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GROUNDING
3.3.10 Ground lighting fixtures to the green grounding conductor of the wiring system. During renovation, provide the green ground if it is not part of the system, or ground the fixtures through the conduit systems per means acceptable under the NEC. Fixtures connected with flexible conduit shall have a green ground wire included with the power wires from the fixture through the flexible conduit to the first outlet box.
3.3.11 Fixed electrical appliances and equipment shall have a ground lug installed for termination of the green ground conductor.
3.4 CONDUCTIVE PIPING:
3.4.1 Bond all conductive piping systems in the building to the electrical system ground. Bonding connections shall be made as close as practical to the water pipe ground or service equipment ground bus.
3.5 GROUND RESISTANCE:
3.5.1 Grounding system ground resistance must comply with NEC. Provide additional ground rods as required until resistance reading is compliant with NEC.
3.5.2 Services at power company interface points shall comply with the power company ground resistance requirements.
3.5.3 Make necessary modifications to the ground electrodes for compliance that is needed without additional cost to the Owner, including the provisions of a multi-rod system.
3.6 GROUND ROD INSTALLATION:
3.6.1 Drive each rod vertically in the earth for not less than ten feet in depth.
3.6.2 Where permanently concealed ground connections are required, make the connections by the exothermic process to form solid metal joints. Make accessible ground connections with mechanical pressure type ground connectors.
3.6.3 Where rock prevents the driving of vertical ground rods, install grounding electrodes in horizontal trenches to achieve the specified resistance.
3.6.4 In handhole, install ground rods with 4 to 6 inches above the floor with connections of grounding conductors fully visible and accessible.
4.19 16450-7 394.107.001 SECTION 16450
GROUNDING
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - GROUNDING:
4.1.1 The quantity of Grounding for which payment will be made will include all that equipment, accessories, appurtenances or other work as specified herein and required for a complete operating control system.
4.2 PAYMENT - GROUNDING:
4.2.1 For Grounding, not included in other unit or lump sum price items, payment for Grounding will be made at the applicable price stated in the Bid.
END OF SECTION
4.19 16450-8 394.107.001 SECTION 16468
PAD MOUNTED TRANSFORMERS
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Pad Mounted Transformers, as shown on the Plans, as specified and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 Military Specification (Mil. Spec.):
MIL-P-28641 Primer Coating, Vinyl Chloride-Acetate Copolymer, High-Build (For Steel and Masonry)
1.2.2 American National Standards Institute (ANSI) Publications:
C2 National Electrical Safety Code
C12.4 Mechanical Demand Registers
C12.10 Watthour Meters
C57.12.00 Liquid-Immersed Distribution, Power, and Regulating Transformers
C57.12.26 Transformers - Pad-Mounted Compartmental-Type, Self-Cooled, Three-Phase Distribution Transformers for Use with Separable Insulated High-Voltage Connectors, High-Voltage 34 500 Grd Y/19 920 Volts and Below; 2500 kVA and Smaller
C57.12.90 Test Code for Liquid-Immersed Distribution, Power, and Regulating Transformers and Guide for Short-Circuit Testing of Distribution and Power Transformers
4.19 16468-1 394.107.001 SECTION 16468
PAD MOUNTED TRANSFORMERS
C57.13 Instrument Transformers
Z35.1 Accident Prevention Signs
1.2.3 American Society for Testing and Materials (ASTM) Publications:
D92 Flash and Fire Points by Cleveland Open Cup
D117 Electrical Insulating Oils of Petroleum Origin
D877 Dielectric Breakdown Voltage of Insulating Liquids Using Disk Electrodes
D3487 Mineral Insulating Oil Used in Electrical Apparatus
1.2.4 Institute of Electrical and Electronic Engineers Inc. (IEEE) Publication:
386 Separable Insulated Connector Systems for Power Distribution Systems Above 600 V
1.2.5 National Electrical Manufacturers Association (NEMA) Publication:
LA 1 Surge Arresters
1.2.6 National Fire Protection Association (NFPA) Publication:
70 National Electrical Code
1.2.7 Underwriters Laboratories Inc. (UL) Publications:
414 Meter Sockets
489 Molded-Case Circuit Breakers and Circuit-Breaker Enclosures
4.19 16468-2 394.107.001 SECTION 16468
PAD MOUNTED TRANSFORMERS
1.3 GENERAL REQUIREMENTS: General requirements include those specified in Section 16011, "Electrical General Requirements", and as specified herein. The work includes the provision of new pad mounted transformers, for outdoor use. Materials not normally furnished by the manufacturer with the equipment are specified elsewhere.
1.4 SUBMITTALS:
1.4.1 Shop Drawings:
a. Pad Mounted Transformers: Shop drawing shall indicate, but not be limited to the following:
1) Overall dimensions, front view, and sectional views.
2) Elementary diagrams and wiring diagrams with terminals identified, and indicating internal wiring for and interconnection between each item of equipment. 3) Manufacturer’s descriptive literature of cataloged products, equipment drawings, diagrams, performance, characteristics and specifications. 4) Complete information on materials and finishes used. 5) Layout and arrangement of equipment, accessories and any items required to assure a coordinated installation. 6) Unit dimensions and weights, including weight distribution. 7) Clearances for operation, maintenance and replacement of equipment and/or components. 8) Where installation procedures or any part thereof are required to be in accordance with the recommendations of the manufacturer of the material being installed, printed copies of these recommendations shall be furnished prior to installation. 9) Installation requirements to meet seismic Design Criteria (SDC = “C”, SIF = 1.0).
b. Transformer Rating Submittal: Submit information on the following:
1) Core Losses at 85 deg C or at 20 deg C 2) Winding Losses 3) Excitation Current @ 100% and at 110% rated Voltage 4) Percent Impedance
4.19 16468-3 394.107.001 SECTION 16468
PAD MOUNTED TRANSFORMERS
5) Efficiency at 100%, 75%, 50%, and 25% Load 6) Percent regulation at 0.8 and 1.0 PF 7) DOE Certification
1.4.2 Manufacturer's Data:
a. Pad Mounted Transformer b. Pad Mounted Transformer Pad/Vault c. 200A load break bushing wells and inserts d. 200A Load Break Connectors and Caps e. MOVE Elbow Surge Arresters
1.4.3 Certified Laboratory Test Reports: Submit certified copies of the following ANSI C57.12.00 and C57.12.90 transformer tests:
a. Routine Tests: Certify that routine tests shall be conducted by the manufacturer on each transformer to insure that design performance is maintained in production.
b. Design Tests: Submit design test reports for certification of conformance to design test requirements.
c. Other Tests: Other tests will be acceptable as defined in ANSI C57.12.00.
PART 2 – PRODUCTS
2.1 TRANSFORMERS:
a. Connection shall be three phase. Note that these transformers are to be utilized as a step up (480V-4.16kV) and then step down (4.16kV-480V) configuration. Refer to drawings for delta-grounded wye required configuration for each transformer. b. %Z per NEMA standards c. 2 ½% FCAN and 2 ½% FCBN Taps d. Impedance: 5.75%Z +/-7.5% Tolerance e. Efficiency: 99.25% (min) at 50% load f. 5kV side BIL: 95kV g. 480V side BIL: 30 kV h. 65 degree C temp.
4.19 16468-4 394.107.001 SECTION 16468
PAD MOUNTED TRANSFORMERS
i. Provide as loop feed 5kV connections with two sets of primary bushing wells for loop feed for each phase j. Bushing well inserts k. Bay-o-net fusing with drip tray l. 600V class low voltage bushings m. No-load tap changer on 5kV windings n. Under oil transformer on/off switch o. Outdoor - FR3 liquid filled p. Sound level, as measured by the NEMA audible sound-level test procedure, shall be less than the values specified in NEMA TR-1 for liquid-filled transformers.
2.2 INSULATING LIQUIDS:
2.2.1 Less Flammable Transformer Liquids: NFPA 70 and Factory Mutual Approval Guide for "less-flammable" liquids having a minimum fire point of 300 degrees C tested in accordance with ASTM D92 and a minimum dielectric strength of 33kV tested in accordance with ASTM D877. Insulating liquids containing polychlorinated biphenyls (PCB's) or tetrachloroethylene (perchloroethylene) are prohibited.
2.3 UNDERCOATING: Coat the underside of transformer bases with a 4-mil thick coating conforming to Mil. Spec. MIL-P-28641.
2.4 NAMEPLATES: Provide transformer nameplates conforming to ANSI C57.12, except indicate the number of gallons of coolant.
2.5 WARNING SIGNS: ANSI Z35.1. Provide metal signs reading "DANGER HIGH VOLTAGE" on two lines in letters of minimum 3-inch height.
2.6 PAD MOUNTED TRANSFORMER: Outdoor type, consisting of a high-voltage (5kV class) compartment, a transformer section, and a low-voltage (600V class) compartment separated by full height isolating barriers. Components shall be assembled and shipped by one manufacturer as a unit, completely weatherproof and tamperproof for mounting on a concrete pad without additional housing, fences or other enclosures. Unit shall conform to applicable portions of ANSI C57.12.26, modified as necessary to accommodate the components specified herein. Component ratings shall be as indicated, and as specified herein.
2.6.1 Primary Components: The primary compartment shall be dead-front construction and shall include:
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PAD MOUNTED TRANSFORMERS
a. 4.16kV winding side shall be loop feed with two (2) bushing wells per phase (“A” and “B” bushing wells for a total of six (6) 15kV rated bushing wells). b. Provide each “A” side bushing well with a 15kV class rotatable feedthrough insert. One side of each insert is for an elbow cable connector, the other side is for an elbow arrestor (MOVE surge arrestor). c. Provide each “B” side bushing well with a single insert. Provide each single insert with a loadbreak protective cap. The “B” side bushings are for future loop extensions if necessary. d. Provide a loadbreak rated under oil “On/Off” disconnect switch. e. Bay-o-net fuses shall be accessible from the primary compartment. f. Provide a minimum of six (6) cable parking stands.
2.6.1.1 Load break connectors shall be the separable insulated type rated 95kV basic insulation level (BIL), 200 amps and in conformance with IEEE 386. Associated bushing wells, inserts, and insulated bushings shall be compatible with the load break connectors.
2.6.1.2 Provide a parking stand near each bushing well. Provide three insulated standoff bushings for parking of energized load break connectors on parking stands.
2.6.1.3 Oil switch: Gang operated, under oil, On/Off transformer primary disconnect switch. Switch shall be rated 95 kV BIL, 200 amperes continuous and load break, and 10,000 amperes momentary.
2.6.1.4 Fuses: Current limiting, bay-o-net type fuses ; Draw-out expulsion fuse in combination with internally mounted partial-range current limiting fuse or isolation link. Provide drip tray. Fuses shall be sized per transformer manufacturer’s recommendations.
2.6.1.5 Surge Arresters: NEMA LA 1, fully shielded, dead front, elbow type arresters suitable for plugging onto feed-thru inserts. Arrestors shall be:
a. 3kV with 2.55kV MCOV (maximum continuous operating voltage) rating for utilization on grounded 4.16 kV/2.4kV grounded wye system. b. 6kV Rated with 5.1kV MCOV (maximum continuous operating voltage) rating for utilization on ungrounded 4.16 kV delta system.
2.6.2 Transformer Section: Transformer shall be three-phase, two winding, 60 Hz, 65 degree C rise, FR3less flammable liquid, self-cooled type. Transformer shall have a sealed tank with a welded cover. Provide the following accessories:
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PAD MOUNTED TRANSFORMERS
a. Drain and sampling valves b. External no-load tap changer with position indicator for de-energized operation only. Provide with two 2 ½ percent full capacity taps above and below rated 4.16kV voltage. Locate changer control handle within the high voltage compartment and provide means to prevent unintentional operation. c. Filter press connections d. Ground pads e. Provision for lifting and jacking f. Top liquid dial-type thermometer without alarm contacts g. Pressure-vacuum gauge h. Pressure-relief device
2.6.3 Outgoing Compartment: Include low voltage bushings, spade-type terminals.
2.7 TRANSFORMER PAD: Refer to contract drawings for transformer pad/vault. Place on well compacted gravel subbase (minimum of 12”) so that top surface of transformer pad is 4 inches above grade. Determine cable entrance space and location according to requirements of equipment to be mounted.
2.8 GROUND RODS: Copper clad steel to permit driving full length to a minimum depth of 6 inches below finished grade. Minimum dimensions of rods shall be 3/4 inch diameter, and 10 ft. length.
PART 3 - EXECUTION
3.1 INSTALLATION: Conform to the manufacturer's shop drawings and mounting instructions including securing the transformer to the concrete slab with a minimum of four anchor bolts. Completed installation shall conform to the requirements of ANSI C2.
3.2 GROUNDING: Pad mounted transformer shall have grounded pads, lightning arrestors, protective fencing connected to a solid earth ground using cone pointed driven ground rods in accordance with paragraph in this section, entitled, "Ground Rods". Install as indicated to provide an earth ground having a minimum test resistance of 5 ohms.
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3.2.1 Connections: Buried or otherwise inaccessible grounding connections except those which specifically require access for periodic testing, shall be made by exothermic weld or completely brazed compatible mechanical connector. Welds which have "puffed up" or have convex surfaces indicate improper cleaning and will be rejected.
3.3 SIGNS: Install "DANGER HIGH VOLTAGE" signs with tamper-proof screws on each side of pad mounted transformers, except when the transformer is surrounded by a fence, mount the signs on each side of the fence.
3.4 FIELD QUALITY CONTROL:
3.4.1 Field Tests: Upon completion of installation, notify the Engineer 5 days in advance of the proposed operating test. Verify by demonstration that equipment and devices are operating satisfactorily.
3.4.2 Ground Rod Test: Test ground rods for ground resistance value before connecting wire. Test each ground rod or group of rods with a portable ground testing megger, equipped with a meter that indicates the ground value of the electrode being tested directly in ohms or fractions thereof. Provide one copy of the megger manufacturer's directions for use of the ground megger and indicate the method to be used.
3.4.3 Test Reports:
a. Grounding electrodes and systems: Identify each ground and record test value.
b. Manufacturer to provide certified test reports in accordance with ANSI C57.12.26. Routine tests are minimum or other tests as required by the Owner/Engineer.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT – PAD MOUNTED TRANSFORMERS:
4.1.1 Measurement for Pad Mounted Transformers shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
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4.2 PAYMENT – PAD MOUNTED TRANSFORMERS:
4.2.1 For Pad Mounted Transformers, not included in other unit or lump sum price items, payment for Pad Mounted Transformers will be made at the applicable price stated in the Bid.
END OF SECTION
4.19 16468-9 394.107.001 SECTION 16510
INTERIOR LIGHTING
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Interior Lighting, as shown on the Plans, as specified, and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 American National Standards Institute, Inc. (ANSI) Publications:
C78.41 Electric Lamps - Low-Pressure Sodium Lamps
C78.1350 Electric Lamps - 400-Watt S51 High-Pressure Sodium Lamps
C78.1351 250-Watt S50 High-Pressure Sodium Lamps
C78.1352 1000-Watt S52 High-Pressure Sodium Lamps
C78.1353 Electric Lamps - 70-Watt S62 High-Pressure Sodium Lamps
C78.1354 Electric Lamps - 100-Watt S54 High-Pressure Sodium Lamps
C78.1355 150-Watt 55-Volt S55 High-Pressure Sodium Lamps
C78.1358 Electric Lamps - 35-Watt S76 High-Pressure Sodium Lamps
C78.1359 Electric Lamps - 50-Watt S68 High-Pressure Sodium Lamps
C78.1375 400-Watt M59 Metal-Halide Lamp
C78.1376 Electric Lamps - 1000-Watt M47 Metal-Halide Lamps
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C78.1377 Electric Lamps - 175-Watt M57 Metal-Halide Lamps
C82.1 Ballasts for Fluorescent Lamps
C82.2 Fluorescent Lamp Ballasts - Methods of Measurement
C82.4 Ballasts for High-Intensity-Discharge and Low-Pressure Sodium Lamps (Multiple-Supply Type)
1.2.2 American Society for Testing and Materials (ASTM) Publications:
A366/A366M Steel, Sheet, Carbon, Cold-Rolled, Commercial Quality
A526/A526M Steel Sheet, Zinc-Coated (Galvanized) by the Hot-Dip Process, Commercial Quality
A580 Stainless and Heat-Resisting Steel Wire
B633 Electrodeposited Coatings of Zinc on Iron and Steel
1.2.3 Federal Communications Commission (FCC) Publication:
RR Rules and Regulations, Vol. II, Transmittals 1 through 6
1.2.4 Federal Specifications (FS):
QQ-N-281 Nickel-Copper Alloy Bar, Rod, Plate, Sheet, Strip, Wire, Forgings, and Structural and Special Shaped Sections
QQ-W-461 Wire, Steel, Carbon (Round, Bare and Coated)
1.2.5 Illuminating Engineering Society (IES) Publication:
LHBK Lighting Handbook, Reference and Application Volumes
1.2.6 Institute of Electrical and Electronics Engineers (IEEE) Publication:
STD587 Surge Voltages in Low-Voltage AC Power Circuit (ANSI/IEEE C62.41)
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INTERIOR LIGHTING
1.2.7 National Electrical Manufacturers Association (NEMA) Publications:
ICS2 Industrial Control Devices, Controllers, and Assemblies
ICS6 Enclosures for Industrial Controls and Systems
1.2.8 National Fire Protection Association (NFPA) Publications:
70 National Electrical Code
101 Code For Safety to Life From Fire in Buildings and Structures
1.2.9 Underwriters Laboratories, Inc. (UL) Publications:
20 General-Use Snap Switches
773 Plug-In, Locking Type Photocontrols for Use With Area Lighting
773A Nonindustrial Photoelectric Switches for Lighting Control
844 Electric Lighting Fixtures for Use in Hazardous (Classified) Locations
924 Emergency Lighting and Power Equipment
935 Fluorescent-Lamp Ballasts
1029 High-Intensity-Discharge Lamp Ballasts
1570 Fluorescent Lighting Fixtures
1571 Incandescent Lighting Fixtures
1572 High Intensity Discharge Lighting Fixtures
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INTERIOR LIGHTING
1.3 RELATED REQUIREMENTS: Section 16011, "Electrical General Requirements", applies to this Section, with the additions and modifications specified herein. Lighting fixtures and accessories mounted on exterior surfaces of building are specified in this Section.
1.4 SUBMITTALS: Submit the following. Data, drawings, and reports shall employ the terminology, classifications, and methods prescribed by the IES LHBK, as applicable, for the lighting system specified.
1.4.1 Manufacturer's Catalog Data:
a. Lighting fixtures
b. Lamps
c. Ballasts
d. Lighting contactors
e. Photocell switch
f. Time switch
g. Dimmer switch
h. Power hooks
i. Emergency lighting equipment
j. Support hangers for lighting fixtures in suspended ceilings
1.4.2 Drawings:
a. Lighting fixture assemblies
b. Emergency lighting systems
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INTERIOR LIGHTING
PART 2 - PRODUCTS
2.1 FLUORESCENT LIGHTING FIXTURES: UL 1570.
2.1.1 Fluorescent Lamps: Provide the number, type, and wattage indicated.
2.1.2 Fluorescent Core and Coil Ballasts: UL 935, ANSI C82.1, and shall be labeled Certified Ballast Manufacturers (CBM) certified by Electrical Testing Laboratories (ETL). Fixtures and ballasts shall be designed and constructed to limit the ballast case temperature to 90 degrees Celsius (C) when installed in an ambient temperature of 40 degrees C.
2.1.2.1 Low Temperature Ballasts: Provide fluorescent ballasts having a minimum starting temperature of zero degrees F in fixtures mounted and as indicated.
2.1.2.2 Energy-Saving Ballasts: Provide energy-saving fluorescent ballasts of the CBM certified full light output type.
2.1.3 Fluorescent Solid-State Ballasts: Provide energy-saving, solid-state fluorescent ballast of the full light output type. Electromagnetic interference shall not be greater than that allowed by the FCC RR Part 18 for RF lighting devices. The ballasts shall be able to withstand voltage transients in accordance with IEEE STD587, Category A, for normal and common modes. Minimum power factor shall not be less than 0.90. The ballasts shall operate at a frequency not less than 20,000 hertz. Ballast current third harmonic content shall be less than 33 percent. Ballast shall be compatible for use with energy-saving lamps.
2.1.4 Open-tube Fluorescent Fixtures: Provide with spring-loaded telescoping sockets, self-locking sockets, or lamp retainers (two per lamp).
2.1.5 Electromagnetic Interference Filters: Provide in each fluorescent fixture. Filters shall be integral to the fixture assembly with one filter per ballast and shall suppress electromagnetic interference in the AM radio band from 500 to 1700 kHz.
2.3 INCANDESCENT LIGHTING FIXTURES: UL 1571.
2.3.1 Incandescent Lamps: Provide the number, type, and wattage indicated.
2.4 RECESS- AND FLUSH-MOUNTED FIXTURES: Provide type that can be relamped from the bottom. Access to ballast shall be from the bottom. Trim for the exposed surface of flush-mounted fixtures shall be as indicated.
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INTERIOR LIGHTING
2.5 SUSPENDED FIXTURES: Provide hangers capable of supporting twice the combined weight of the fixtures supported by the hangers. Provide with swivel hangers to ensure a plumb installation. Hangers shall be cadmium-plated steel with a swivel-ball tapped for the conduit size indicated. Hangers shall allow fixtures to swing within an angle of 20 degrees. Brace pendants 4 feet or longer to limit swinging. Single-unit suspended fixtures shall have twin-stem hangers.
Multiple-unit or continuous row fluorescent fixtures shall have a tubing or stem for wiring at one point and a tubing or rod suspension provided for each unit length of chassis, including one at each end. Rods shall be a minimum 3/16-inch diameter.
2.6 FIXTURES FOR HAZARDOUS LOCATIONS: In addition to requirements stated elsewhere in this Section, provide fixtures for hazardous locations which conform to UL 844 or which have Factory Mutual certification for the class and division indicated.
2.7 Occupancy Sensors: Provide UL and CUL3d62 listed sensor with adjustable time delay and combination PIR detection to sense occupancy and noise level within the space to turn lights on.
2.7.1 Ceiling Mounted: Sensor shall provide 360 degrees coverage over 900 square feet coverage area with multiple sensor capability. Mounting shall be suitable for ceiling construction anticipated. Sensor shall be as manufactured by Sensor Switch Dual Technology CMR-PDT type, or equal.
2.7.2 Wall Mounted: Sensor shall be decorator design type with three-way switching capability and 900 square feet coverage area. Sensor shall be as manufactured by Sensor Switch Dual Technology WDS-PDT type, or equal.
2.8 EXIT SIGNS: UL 924, NFPA 70, and NFPA 101. Exit signs shall be as indicated
2.8.1 Self-powered Exit Signs (Battery Type): Provide with automatic power failure device, test switch, pilot light, and fully automatic high/low trickle charger in a self-contained power pack. Battery shall be sealed electrolyte type, shall operate unattended, and require no maintenance (including additional water) for a period of not less than 5 years.
2.8.2 Remote-powered Exit Signs: Provide remote ac/dc exit signs with provisions for wiring to external ac and dc power sources. Provide signs with a minimum of two ac lamps for normal illumination and a minimum of two dc lamps for emergency lighting.
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INTERIOR LIGHTING
2.9 EMERGENCY LIGHTING EQUIPMENT: UL 924, NFPA 70, and NFPA 101. Provide lamps in wattage indicated. Provide accessories required for remote-mounted lamps where indicated. Remote-mounted lamps shall be as indicated.
2.9.1 Emergency Lighting Unit: Provide as indicated.
PART 3 - EXECUTION
3.1 INSTALLATION: Set lighting fixtures plumb, square, and level with ceiling and walls, in alignment with adjacent lighting fixtures, and secure in accordance with manufacturers' directions and approved drawings. The installation shall meet with the requirements of NFPA 70. Mounting heights specified or indicated shall be to bottom of fixture for ceiling-mounted fixtures and to center of fixture for wall-mounted fixtures. Obtain approval of the exact mounting for lighting fixtures on the job before installation is commenced and, where applicable, after coordinating with the type, style, and pattern of the ceiling being installed. Recessed and semi-recessed fixtures may be supported from suspended ceiling support system ceiling tees if the ceiling system support wires or rods are provided at a minimum of four wires or rods per fixture and located not more than 6 inches from each corner of each fixture. Additionally, for recessed fixtures, provide support clips securely fastened to ceiling grid members, a minimum of one at or near each corner of each fixture. For round fixtures or fixtures smaller in size than the ceiling grid, provide a minimum of four wires or rods per fixture and locate at each corner of the ceiling grid in which the fixture is located. Do not support fixtures by ceiling acoustical panels. Where fixtures of sizes less than the ceiling grid are indicated to be centered in the acoustical panel, support such fixtures independently or with at least two 3/4-inch metal channels spanning, and secured to, the ceiling tees. Provide wires or rods for lighting fixture support in this Section.
3.1.1 Exit and Emergency Lights: Wire exit lights on separate circuits and serve from a separate breaker. Lights shall have only one control, which shall be the circuit breaker in the panel. Wire emergency lights ahead of the switch to the normal lighting circuit located in the same room or area.
3.2 FIELD QUALITY CONTROL: Upon completion of the installation, conduct an operating test to show that the equipment operates in accordance with the requirements of this Section.
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INTERIOR LIGHTING
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - INTERIOR LIGHTING:
4.1.1 Measurement for Interior Lighting shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
4.2 PAYMENT - INTERIOR LIGHTING:
4.2.1 For Interior Lighting, not included in other unit or lump sum price items, payment for Interior Lighting will be made at the applicable price stated in the Bid.
END OF SECTION
4.19 16510-8 394.107.001 SECTION 16859
ELECTRICAL - HEATING CABLES
PART 1 - GENERAL
1.1 DESCRIPTION:
1.1.1 Under this Section, the Contractor shall furnish all labor, materials and equipment for Electrical - Heating Cables as shown on the Plans, as specified and/or directed.
1.2 REFERENCES: The publications listed below and their latest revisions form a part of this Specification to the extent referenced. The publications are referred to in the text by the basic designation only.
1.2.1 National Fire Protection Association (NFPA) Publication:
70 National Electrical Code
1.2.2 Underwriters Laboratories, Inc. (UL) Publication:
Approval List
1.3 GENERAL REQUIREMENTS: Section 16011, "Electrical-General Requirements", with the additions and modifications specified herein, applies to this Specification. Verify temperature rating, pipe material, pipe size, insulation type and thickness for systems requiring heat trace.
1.4 SUBMITTALS:
1.4.1 Manufacturer's Data: Submit manufacturer's descriptive literature for the following:
a. Heat Trace Cable b. Tee Splices c. End Seals d. Power Connection Assembly e. Thermostat Controller f. Lengths of Piping Systems
1.4.2 Standards Compliance and Manuals: Submit standards compliance information as well as Operation and Maintenance manuals for the equipment furnished.
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1.4.3 Shop Drawings: Furnish shop drawings showing location and details of construction for any openings in slabs and walls for raceway runs. Show circuit lengths, piping systems, and circuit in rush current for lowest expected start-up temperature.
1.4.4 Field Test Results: Submit the results of resistance tests for each circuit prior to the insulation of piping systems and after insulation is installed.
PART 2 - PRODUCTS
2.1 NEW HEAT TRACE CABLE: Heat trace cable shall be self-regulating consisting of a pair of copper bus wires, a self-regulating semi-conductive core and a fluoropolymer jacket. Supply voltage shall be 120 V.A.C. Manufacture shall be as by Raychem, Chromalox, or equal.
2.1.1 Heat Trace Cable Schedule: Furnish new heat trace cables in accordance with the following schedule. Install one complete heat trace circuit for each piping system.
Output Rate at 120 VAC System Ins. Thickness (w/ft.)
Leachate Piping 2 Inch 5
2.1.2 Thermostat Controller: Ambient sensing thermostat shall be industrial grade indicating type suitable for 120 V service. Temperature range shall be 15-140oF. Enclosure shall be NEMA 4X epoxy coated cast aluminum.
2.1.3 Accessories: Furnish with all accessories required for a complete system including pipe strap and glass tape, tee splice kits, end termination kits, power connection kits with junction box and clamps for securing to pipe and conduit.
2.2 INSULATION: Furnish with all components required for a complete system.
2.2.1 Material: Furnish and install 2-inch thick polyisocyanurate rigid pipe insulation or approved equal for all pipes, fittings and valves that are to be heat traced.
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2.2.2 Jacket: White kraft outer surface bonded to aluminum foil and reinforced with fiberglass yarn permanently treated for fire and smoke safety, as well as prevent corrosion of the foil. Tape all joints with tape matching jacket construction. Provide molded PVC covers at fittings to be by Johns-Manville, or approved equal.
2.2.3 Covering Over Jacket, Exposed Outdoor and Wet Locations: Furnish and install 0.016 aluminum jacket complying with ASTM B2009 with ¾-inch wide bands 0.007-inch thick. Seal all exposed seams with GE silicone clear sealant to provide a watertight seal.
PART 3 - EXECUTION
3.1 GENERAL INSTALLATION: Heat trace cables shall be installed in accordance with manufacturer's instructions. Provide services of manufacturer’s representative to supervise installation. Heat trace cables shall extend the entire length of the exposed piping as indicated on the Contract Drawings. Attach to pipe every 12 inches using metallic banding. Install on outside radius of piping elbow. Install along the length of piping at an angle 45o from the piping invert. Install on all fittings in those areas designated to be heat traced. Each cable length shall not exceed manufacturer’s recommended maximum length. Install end seals at ends of circuits. Provide power connection fitting and conduit junction box at each power connection point. Install ambient sensing thermostat as recommended by manufacturer. Provide sensing thermostat.
3.2 INSULATION: Insulate piping as soon as possible after heat tracing is installed. When piping is insulated and jacketed, install "Electric Traced" labels on outside of jacket where visible from normal operations or every ten feet. Mark jacketing where connection points are located below insulation.
3.3 TESTS: Perform testing of the electrical resistance of each circuit when completed but before insulation is installed, and once again after pipe is insulated and jacketed.
PART 4 - MEASUREMENT & PAYMENT
4.1 MEASUREMENT - ELECTRICAL - HEATING CABLES:
4.1.1 Measurement for Electrical - Heating Cables shall include the cost of all materials, equipment, labor, submittals and testing for the work indicated in this Section.
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ELECTRICAL - HEATING CABLES
4.2 PAYMENT - ELECTRICAL - HEATING CABLES:
4.2.1 For Electrical - Heating Cables, not included in other unit or lump sum price items, payment for Electrical - Heating Cables will be made at the applicable price stated in the Bid.
END OF SECTION
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