Florida Governmental Utility Authority
Lee County Utilities Waterway Estates Interconnect
JANUARY 2011
60% SUBMITTAL TECHNICAL SPECIFICATIONS
CDM 12501 World Plaza Lane, Building 51 Fort Myers, FL 33907 Phone: (239) 938-9600 Fax: (239) 2756755 Florida Governmental Utility Authority Waterway Estates Interconnect 60% Submittal
TABLE OF CONTENTS
DIVISION 1 – GENERAL REQUIREMENTS
01010 SUMMARY OF WORK 01046 CONTROL OF WORK 01050 FIELD ENGINEERING 01052 APPLICATIONS FOR PAYMENT 01110 ENVIRONMENTAL PROTECTION PROCEDURES 01200 PROJECT MEETINGS 01300 SUBMITTALS 01370 SCHEDULE OF VALUES 01390 CONSTRUCTION PHOTOGRAPHS 01410 TESTING AND TESTING LABORATORY SERVICES 01445 PIPELINE TESTING AND CLEANING 01520 CONSTRUCTION AIDS 01540 SECURITY 01580 PROJECT IDENTIFICATION AND SIGNS 01600 DELIVERY, STORAGE, AND HANDLING 01660 PRESSURE TESTING 01700 CONTRACT CLOSEOUT 01710 CLEANING 01720 PROJECT RECORD DOCUMENTS 01740 WARRANTIES AND BONDS
DIVISION 2 – SITEWORK
02100 SITE PREPARATION 02140 DEWATERING AND DRAINAGE 02151 JACKING 02221 TRENCHING, BACKFILLING, AND COMPACTION 02222 ROADWAY CROSSINGS BY OPEN CUT 02230 GRANULAR MATERIALS 02270 EROSION AND SEDIMENTATION CONTROL 02413 HORIZONTAL DIRECTIONAL DRILLING 02515 SIDEWALKS, DRIVEWAYS AND CURBS 02576 PAVEMENT REPAIR AND RESTORATION 02607 SEWER MANHOLES 02616 DUCTILE IRON PIPE AND FITTINGS 02620 HIGH DENSITY POLYETHYLENE PIPE AND FITTINGS 02622 POLYVINYL CHLORIDE (PVC) FORCE MAIN PIPE 02640 VALVES, HYDRANTS AND APPURTENANCES 02658 CONNECTIONS TO AND WORK ON THE EXISTING SYSTEM 02661 PIPELINE CLEANING 02930 LAWN RESTORATION
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DIVISION 3 – CONCRETE
03100 CONCRETE FORMWORK 03200 CONCRETE REINFORCEMENT 03250 CONRETE JOINTS AND JOINTS ACCESSORIES 03300 CAST-IN-PLACE CONCRETE 03410 PRECAST CONCRETE STRUCTURES 03600 GROUT
DIVISION 5 – METALS
05500 MISCELLANEOUS METAL
DIVISION 9 – FINISHES
09901 SURFACE PREPARATION AND SHOP PRIME PAINTING 09902 PAINTING
DIVISION 11 – EQUIPMENT
11208 SUBMERSIBLE SEWEAGE PUMPS 11258 BIOLOGICAL ODOR CONTROL SYSTEM EQUIPMENT 11303 SUBMERSIBLE PUMPING STATION
DIVISION 13 SPECIAL CONSTRUCTION
13300 PROCESS INSTRUMENTATION AND CONTROLS – GENERAL PROVISIONS 13305 APPLICATION ENGINEERING SERVICES 13315 FIELD INSTRUMENTATION 13325 CONTROL PANELS AND PANEL MOUNTED EQUIPMENT
DIVISION 15 – MECHANICAL
15110 WASTEWATER VALVES AND APPURTENANCES
DIVISION 16 – ELECTRICAL
16000 ELECTRICAL – GENERAL PROVISIONS 16110 RACEWAYS, BOXES, FITTINGS AND SUPPORTS 16120 WIRES AND CABLES 16150 MOTORS 16191 MISCELLANEOUS EQUIPMENT 16217 DIESEL ENGINE DRIVEN GENERATOR (SELF CONTAINED WITH MODULAR WEATHERPROOF ENCLOSURE AND SUB-BASE FUEL TANK)
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16370 VARIABLE FREQUENCY DRIVES 16470 PANELBOARDS 16500 LIGHTING SYSTEM 16600 UNDERGROUND SYSTEM 16660 GROUNDING SYSTEM
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SECTION 01010
SUMMARY OF WORK
PART 1 GENERAL
1.01 DEFINITIONS
A. The ENGINEER is Camp Dresser & McKee Inc.
B. The obligations of CONTRACTOR to ENGINEER as provided for in the Contract Documents shall be deemed to be the obligations of SUBCONTRACTOR to CDM Constructors Inc.
C. When necessary to make the context of the Contract document clauses reflect the contractual relationship established and intended herein, the term ENGINEER shall mean CDM Constructors Inc., except the term ENGINEER does not change when a right, act, authorization or obligation can be granted or performed only by the ENGINEER or its duly authorized representative.
D. The obligations of SUBCONTRACTOR to CONTRACTOR as provided for in the Contract Documents shall be deemed to be the obligations of SUBCONTRACTOR to CDM Constructors Inc.
E. The obligations of CONTRACTOR to Owner as provided for in the Contract Documents shall be the obligations of SUBCONTRACTOR to CDM Constructors Inc.
F. The County is Lee County.
1.02 LOCATION OF WORK
A. The general location of this work is within the defined boundaries of Lee County. The construction of force mains will occur within existing County and Florida Department of Transportation Right of Way.
1.03 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required and construct new intermediate dump station improvements to Lift Station LS01, and install approximately 37,000 lf of force main, using various installation techniques to include open cutting, jack and bore, and horizontal directional drilling, in its entirety as shown on the Drawings and specified herein.
B. The Work includes, but is not necessarily limited to, the following:
1. Site work Cleaning and grubbing Erosion and sedimentation control measures Seeding and sodding Permanent replacement
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Cure replacement Sidewalk replacement Driveway replacement
2. Excavation and backfill
3. Finished force main, and piping, testing.
4. Trenchless installation of piping under highway and various crossings as shown on the plans.
5. Proper disposal and management of drilling fluids and all drilling by-products.
1.04 OWNER OCCUPANCY
A. Owner will maintain the existing pump stations and force mains during performance of the work for the conduct of normal operations. Coordinate all construction operations with CDM to minimize conflict and to facilitate Owner usage.
1.05 CONTRACTOR’S USE OF PREMISES
A. The Contractor shall have use of the premises as indicated on the drawings for the performance of the Work.
B. Coordinate use of premises with ENGINEER.
C. Contractor shall assume full responsibility for security and safety of all his and his subcontractors’ materials and equipment stored on the site or along the road right-of-way (ROW) corridors..
D. If directed by the Owner or Engineer, move any stored items which interfere with operations of Owner or other contractors.
E. Obtain and pay for use of additional storage or work areas outside the ROW if needed to perform the Work.
1.06 PROJECT REQUIREMENTS
A. This project involves crossing of Florida Department of Transportation (FDOT) highway (Pine Island Road, Cleveland Boulevard, Tamiami Trail, and various side roads and driveways). The Contractor shall follow appropriate FDOT guidelines and regulations for construction under FDOT roadways. These specifications and documents are fully incorporated into this construction project by reference.
END OF SECTION
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SECTION 01046
CONTROL OF WORK
PART 1 GENERAL
1.01 WORKMANSHIP
A. Furnish workmanship and equipment which will be efficient, appropriate and large enough to secure a satisfactory quality of work and a rate of progress which will insure the completion of the work within the Contract Time. If at any time such work force appears to the Engineer to be inefficient, inappropriate or insufficient for securing the quality of work required or for producing the rate of progress aforesaid, he/she may order the Contractor to increase the efficiency, change the character or increase the site equipment and the Contractor shall conform to such order. Failure of the Engineer to give such order shall in no way relieve the Contractor of his/her obligations to secure the quality of the work and rate of progress required.
1.02 PRIVATE LAND
A. The Contractor shall not enter or occupy private land outside of easements or ROW, except by permission of the land owner and CDM. All private land usage, if initiated by the Contractor, shall be paid for by the Contractor and the Contractor shall be solely responsible for safety and damages by their activity.
1.03 PIPE LOCATIONS
A. Pipelines shall be located substantially as indicated on the Drawings, but the Engineer reserves the right to make such modifications in locations as may be found desirable to avoid interference with existing structures or for other reasons. Where fittings are noted on the Drawings, such notation is for the Contractor's convenience and does not relieve him/her from laying and jointing different or additional items where required.
1.04 OPEN EXCAVATIONS
A. All open excavations shall be adequately safeguarded by providing temporary barricades, caution signs, lights and other means to prevent accidents to persons and damage to property. The Contractor shall, at his/her own expense, provide suitable and safe bridges and other crossings for accommodating travel by pedestrians and workmen. Bridges provided for access during construction shall be removed when no longer required. The length or size of excavation will be controlled by the particular surrounding conditions, but shall always be confined to the limits prescribed by the Engineer. If the excavation becomes a hazard, or if it excessively restricts traffic at any point, the Engineer may require special construction procedures such as limiting the length of the open trench, prohibiting stacking excavated material in the street and requiring that the trench shall not remain open overnight.
B. The Contractor shall take precautions to prevent injury to the public due to open trenches. All trenches, excavated material, equipment, or other obstacles which could be dangerous to the public shall be well lighted at night.
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C. The Contractor shall backfill the entire open trench at the end of each day.
D. The Contractor shall be responsible for the removal of any excess excavation material not needed or suitable for backfill material.
1.05 TEST PITS
A. Test pits for the purpose of locating underground pipeline or structures in advance of the construction shall be excavated and backfilled by the Contractor at the direction of the Engineer. Test pits shall be backfilled immediately after their purpose has been satisfied and the surface restored and maintained in a manner satisfactory to the Engineer.
1.06 MAINTENANCE OF TRAFFIC
A. Unless permission to close a street is received in writing from the proper authority, all excavated material shall be placed so that vehicular and pedestrian traffic may be maintained at all times. If the Contractor's operations cause traffic hazards, he/she shall repair the road surface, provide temporary ways, erect wheel guards or fences, or take other measures for safety satisfactory to the Engineer.
B. Detours around construction will be subject to the approval of the authority having jurisdiction in that area. Contractor shall inform the Engineer about approval of the detour. Where detours are permitted, the Contractor shall provide all necessary barricades and signs as required to divert the flow of traffic. While traffic is detoured, the Contractor shall expedite construction operations and periods when traffic is being detoured will be strictly controlled by the Engineer.
C. The Contractor shall take precautions to prevent injury to the public due to open trenches. Night watchmen may be required where special hazards exist, or police protection provided for traffic while work is in progress. The Contractor shall be fully responsible for damage or injuries whether or not police protection has been provided.
D. Traffic control devices shall be placed in accordance with MUTCD 2000 or current edition or as directed by the Engineer.
1.07 CARE AND PROTECTION OF PROPERTY
A. The Contractor shall be responsible for the preservation of all public and private property and shall use every precaution necessary to prevent damage thereto. If any direct or indirect damage is done to public or private property by or on account of any act, omission, neglect, or misconduct in the execution of the work on the part of the Contractor, such property shall be restored by the Contractor, at his/her expense, to a condition similar or equal to that existing before the damage was done, or he/she shall make good the damage in other manner acceptable to the Engineer.
1.08 PROTECTION AND RELOCATION OF EXISTING STRUCTURES AND UTILITIES
A. The Contractor shall assume full responsibility for the protection of all buildings, structures, and utilities, public or private, including poles, signs, services to buildings, utilities in the
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street, gas pipes, water pipes, hydrants, sewers, drains and electric and telephone cables, whether or not they are shown on the Drawings. The Contractor shall carefully support and protect all such structures and utilities from injury of any kind. Any damage resulting from the Contractor's operations shall be repaired by him/her at his/her expense.
B. Contractor shall bear full responsibility for obtaining all locations of underground structures and utilities (including existing telephone cables, water services, force mains, drain lines, gas lines and sewers). Services to buildings shall be maintained, and all costs or charges resulting from damage thereto shall be paid by the Contractor.
C. Protection and temporary removal and replacement of existing utilities and structures as described in this Section shall be a part of the work under the Contract and all costs in connection therewith shall be accounted for in the Total Price Bid in the Bid Form.
D. If, in the opinion of the Engineer, permanent relocation of a utility owned by the County is required due to a direct invert conflict with the work of this Contract, he may direct the Contractor, in writing, to perform the work. Work so ordered will be paid for at the prices bid for applicable pipe items, where applicable, or as extra work under the General Conditions of the Contract where no applicable pipe items exists. If relocation of a privately owned utility is required, the Contractor shall be responsible for contacting the utility owner and coordination of the relocation of the existing utility. The Contractor shall fully cooperate with the Owner and Utility and shall have no claim for delay due to such relocation. The Contractor shall notify all utility companies in writing at least 72 hours (excluding Saturdays, Sundays and Legal holidays) before excavating in any public way. Contractor shall also notify Sunshine State One Call of Florida (SSOCOF) 1-800-432-4770, at least 72 hours prior to start of work.
E. At pipe crossings and where designated by the Engineer, the Contractor shall ensure that the existing utility or pipe is firmly supported for its entire exposed length. The bedding shall extend to the spring line of the pipe crossed.
1.09 WATER FOR CONSTRUCTION AND DRILLING PURPOSES
A. In locations where public water supply is available, the Contractor may be allowed to use water with the approval of the County for construction purposes.
B. The express approval of the County shall be obtained by the Contractor before water is used. Waste of water by the Contractor shall be sufficient cause for withdrawing the privilege of unrestricted use. Hydrants shall only be operated under the supervision of the County’s personnel. The Contractor shall provide a meter and backflow preventer which meets the County’s approval.
1.10 MAINTENANCE OF FLOW
A. The Contractor shall at his/her own cost, provide for the flow of sewers, drains and water courses interrupted during the progress of the work, and shall immediately cart away and remove all offensive matter. The entire procedure of maintaining existing flow shall be fully discussed with the Engineer well in advance of the interruption of any flow.
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1.11 COOPERATION WITHIN THIS CONTRACT AND WITH OTHER CONTRACTORS
A. All firms or persons authorized to perform any work under this Contract shall cooperate with General Contractor and his/her Subcontractors or trades and shall assist in incorporating the work of other trades where necessary or required.
B. Cutting and patching, drilling and fitting shall be carried out where required by the trade or subcontractor having jurisdiction, unless otherwise indicated herein or directed by the Engineer.
1.12 CLEANUP AND DISPOSAL OF EXCESS MATERIAL
A. During the course of the work, the Contractor shall keep the site of his/her operations in as clean and neat a condition as is possible. He/She shall dispose of all residue resulting from the construction work and, at the conclusion of the work, he/she shall remove and haul away any surplus excavation, broken pavement, lumber, equipment, temporary structures, drilling fluid, and any other refuse remaining from the construction operations and shall leave the entire site of the work in a neat and orderly condition. The Contractor shall provide a power broom on site to keep the streets clean of debris daily. The Contractor shall be responsible for containing, hauling, and disposal of all surplus and/or wasted chemicals.
1.13 RESTORATION
A. The Contractor is required to restore all areas to conditions that existed prior to construction. Restoration outside of the pipe trench limits required as a result of the installation of the pipeline shall be at the Contractor's own expense. Restoration within the pipe trench limits is included in the pipe items in the Bid Form.
B. Existing public and private driveways and sidewalks disturbed by the construction shall be replaced to the limits and thicknesses existing prior to construction.
C. Existing signs, lampposts and mailboxes which may be damaged by the Contractor or removed by the Contractor during the course of installing the new pipelines shall be reinstalled in a vertical position at the same location from which they were removed. Damaged items shall be replaced with an item equal to or better than the damaged items. A concrete anchor shall be provided as necessary, at no additional cost, to ensure a rigid alignment. Care shall be exercised in the reinstallation of all items to prevent damage to the newly installed pipelines.
D. Existing concrete, bituminous, timber or granite curbing shall be protected. If necessary, curbing shall be removed and replaced after backfilling. Curbing which is damaged during construction shall be replaced with curbing of equal quality and dimension at the Contractor's expense.
E. Restoration of open cut surfaces within FDOT SR ROW shall be in accordance with FDOT standards and regulations.
1.14 PORT-A-TOILET
A. Port-A-Toilets shall be supplied for each construction crew by the Contractor.
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PART 2: PRODUCTS (Not Used)
PART 3: EXECUTION (Not Used)
END OF SECTION
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SECTION 01050
FIELD ENGINEERING
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Provide and pay for field ENGINEERING services required for project.
1. Survey work required in execution of project.
2. Civil, structural or other professional engineering services specified, or required to execute Contractor's construction methods.
B. Retain the services of a registered land surveyor licensed in the State of Florida:
1. Identify existing control points and property line corner stakes indicated on the Drawings, as required.
2. Verify all existing structure locations within the project site.
3. Maintain an accurate location of all buried piping 4-in in diameter and larger.
4. Provide Certified As-Built drawings by Surveyor.
1.02 RELATED WORK
A. Summary of Work is included in Section 01010
B. Project Record Documents are included in Section 01720.
1.03 SUBMITTALS
A. Submit to the Engineer, in accordance with Section 01300, name and address of registered land surveyor or professional engineer.
B. On request of the Engineer, submit documentation to verify accuracy of field engineering work.
C. Submit certificate signed by registered land surveyor certifying that elevations and locations of improvements are in conformance, or non-conformance, with Contract Documents.
D. At the end of the project, and prior to final payment, submit certified drawings with the Surveyor’s title block (signed and sealed by the registered land surveyor) of the items listed below. These drawings shall be included with, and made a part of, the project record documents.
1. Certified site survey at 1-in = 20-ft scale on sheets 22-in by 34-in, indicating the building corners, sidewalks, paved areas and location of all above ground structures within the project site.
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2. Certified drawing showing the location, lines and grades of all lines 4-in in diameter and larger buried and exterior to buildings and other buried facilities (e.g. valves, vaults, etc) installed as a result of the work. This shall be at the same scale as the Engineer’s piping drawing and submitted on black line reproducible 22-in by 34-in sheets.
3. Certified survey at the same scale as the Engineer's line drawings (e.g. sewer, force main, water transmission, etc) indicating lines, grades, elevations and stationing at 100-ft increments. Provide elevations of structure bottom, pipe invert(s) and rim elevations on all manholes. Submit two signed and sealed copies of as-built drawings along with a CD containing electronic files of these drawings in AutoCAD 2000 or newer version. Electronic format shall match reproducible set.
E. Topographical surveys shall meet the following criteria:
1. 1-in = 20-ft scale reproducible plot, 1 foot contours.
2. Produced on national map accuracy standards for 1-in = 20-ft scale maps with 1 foot contour intervals
3. Contractor shall submit computer generated drawing files in AutoCAD format (Version shall be the same as the Owner’s version) on compact disc(s) (CD). All entries shall be placed on layers named to describe the entity being mapped. All elevation information in the AutoCAD file shall be in an appropriate three dimensional format. A digital terrain model (DTM) AutoCAD file containing adequate three dimensional points and break lines to accurately model the surface shall be submitted. The DTM file shall be compatible for use with AutoCAD (R) Civil 3D software.
F. Survey shall include all the requirements as outlined in Paragraph 1.06 below.
1.04 QUALIFICATIONS OF SURVEYOR
A. Registered land surveyor of the discipline required for the specific service on the project, currently licensed in the State of Florida.
1.05 SURVEY REFERENCE POINTS
A. Existing basic horizontal and vertical control points for the project are those designated on Drawings.
B. Locate and protect control points prior to starting site work and preserve all permanent reference points during construction.
1. Make no changes or relocations without prior written notice to the Engineer.
2. Report to the Engineer when any reference point is lost or destroyed, or requires relocation because of necessary changes in grades or locations.
3. Require surveyor to correctly replace project control points which may be lost or destroyed.
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a. Establish replacements based on original survey control.
1.06 PROJECT SURVEY REQUIREMENTS
A. Establish a minimum of two permanent bench marks on site, referenced to data established by survey control points.
1. Record locations, with horizontal and vertical data, on Project Record Documents.
B. Establish lines and levels, locate and lay out, by instrumentation and similar appropriate means:
1. Site improvements
a. Stakes for grading, fill and topsoil placement.
b. Utility slopes and invert elevations.
C. From time to time, verify layouts by same methods.
D. Establish all lines and grades prior to construction of line work for all force mains, raw water mains and transmission mains at 100-ft increments and at defined breaks in grade.
1.07 RECORDS
A. Maintain a complete, accurate log of all control and survey work as it progresses.
B. Update the project record drawings on a monthly basis based on the work performed during the month ending at the pay request as a condition for approval of monthly progress payment requests.
C. Maintain an accurate record of piping changes, revisions, and modifications.
PART 2 PRODUCTS (NOT USED)
PART 3 EXECUTION (NOT USED)
END OF SECTION
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SECTION 01052
APPLICATIONS FOR PAYMENT
PART 1 GENERAL
1.01 REQUIREMENTS INCLUDED
A. Submit Applications for Payment to the Engineer in accordance with the schedule established by Conditions of the Contract and Agreement between Owner.
B. The accepted Schedule of Values, Section 01370, shall be used as the basis for the Contractor's Application for Payment.
1.02 RELATED WORK
A. Field Engineering is included in Section 01050.
B. Schedule of Values are included in Section 01370.
C. Construction Photographs are included in Section 01390.
D. Contract Closeout is included in Section 01700.
E. Project Record Documents are included in Section 01720.
1.03 SUBMITTALS
A. Submit, in accordance with Section 01300, applications typed on forms provided by the Owner, Application for Payment, with itemized data typed on 8-1/2-in by 11-in or 8-1/2-in by 14-in white paper continuation sheets.
B. Provide itemized data on continuation sheet.
1. Format, schedules, line items and values: Those of the Schedule of Values accepted by the Engineer.
C. Provide construction photographs in accordance with Section 01390.
1.04 PREPARATION OF APPLICATION FOR EACH PROGRESS PAYMENT
A. Application Form
1. Fill in required information, including that for Change Orders executed prior to date of submittal of application.
2. Fill in summary of dollar values to agree with respective totals indicated on continuation sheets.
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3. Execute certification with signature of a responsible officer of Contractor’s firm.
B. Continuation Sheets
1. Fill in total list of all scheduled component items of Work, with item number and scheduled dollar value for each item.
2. Fill in dollar value in each column for each scheduled line item when work has been performed or products stored.
a. Round off values to nearest dollar, or as specified for Schedule of Values.
3. List each Change Order executed prior to date of submission, at the end of the continuation sheets.
a. List by Change Order Number and description, as for an original component item of work.
4. To receive approval for payment on component material stored on site, submit copies of the original paid invoices with the application for payment.
1.05 SUBSTANTIATING DATA FOR PROGRESS PAYMENTS
A. When the Owner or the Engineer requires substantiating data, submit suitable information, with a cover letter identifying.
1. Project.
2. Application number and date.
3. Detailed list of enclosures.
4. For stored products:
a. Item number and identification as shown on application.
b. Description of specific material.
B. Submit one copy of data and cover letter for each copy of application.
C. As a prerequisite for payment, submit a "Surety Acknowledgement of Payment Request" letter showing amount of progress payment which the Contractor is requesting.
D. Maintain an updated set of drawings to be used as record drawings in accordance with Section 01720. As a prerequisite for monthly progress payments, exhibit the updated record drawings for review by the Owner and the Engineer.
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1.06 PREPARATION OF APPLICATION FOR FINAL PAYMENT
A. Fill in Application form as specified for progress payments.
B. Use continuation sheet for presenting the final statement of accounting as specified in Section 01700 - Contract Closeout.
C. Submit all Project Record Documents in accordance with Sections 01050 and 01720.
1.07 SUBMITTAL PROCEDURE
A. Submit Applications for Payment to the Engineer at the times stipulated in the Agreement.
B. Number: Five copies of each Application.
C. When the Engineer finds Application properly completed and correct, he/she will transmit certificate for payment to Owner, with copy to Contractor.
PART 2 PRODUCTS (NOT USED)
PART 3 EXECUTION (NOT USED)
END OF SECTION
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SECTION 01110
ENVIRONMENTAL PROTECTION PROCEDURES
PART 1: GENERAL
1.01 SCOPE OF WORK
A. The work covered by this Section consists of furnishing all labor, materials and equipment and performing all work required for the prevention of environmental pollution in conformance with applicable laws and regulations, during and as the result of construction operations under this Contract. For the purpose of this Specification, environmental pollution is defined as the presence of chemical, physical, or biological elements or agents which adversely affect human health or welfare; unfavorably alter ecological balances of importance to human life; affect other species of importance to man; or degrade the utility of the environment for aesthetic and/or recreational purposes.
B. The control of environmental pollution requires consideration of air, water and land, and involves management of noise and solid waste, as well as other pollutants.
C. Schedule and conduct all work in a manner that will minimize the erosion of soils in the area of the work. Provide erosion control measures such as diversion channels, sedimentation or filtration systems, berms, staked hay bales, seeding, mulching or other special surface treatments as are required to prevent silting and muddying of streams, rivers, impoundments, lakes, etc. All erosion control measures shall be in place in an area prior to any construction activity in that area.
D. These Specifications are intended to ensure that construction is achieved with a minimum of disturbance to the existing ecological balance between a water resource and its surroundings. These are general guidelines. It is the Contractor's responsibility to determine the specific construction techniques to meet these guidelines.
1.02 RELATED WORK
A. Site Preparation is included in Section 02100.
B. Trenching, backfilling and compaction is included in Section 02221.
C. Granular fill materials are included in Section 02230.
D. Lawn restoration is included in Section 02930.
1.03 APPLICABLE REGULATIONS
A. Comply with all applicable Federal, State and local laws and regulations concerning environmental pollution control and abatement.
B. All soil erosion and sediment control activities, provisions and measurers shall comply with the FDOT Erosion and Sediment Control Manual latest edition and NPDES General Permit No. GAR100002 latest edition.
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1.04 NOTIFICATIONS
A. The Engineer will notify the Contractor in writing of any non-compliance with the foregoing provisions or of any environmentally objectionable acts and corrective action to be taken. State or local agencies responsible for verification of certain aspects of the environmental protection requirements shall notify the Contractor in writing, through the Engineer, of any non-compliance with State or local requirements. The Contractor shall, after receipt of such notice from the Engineer or from the regulatory agency through the Engineer, immediately take corrective action. Such notice, when delivered to the Contractor or his/her authorized representative at the site of the work, shall be deemed sufficient for the purpose. If the Contractor fails or refuses to comply promptly, the Owner may issue an order stopping all or part of the work until satisfactory corrective action has been taken. No part of the time lost due to any such stop orders shall be made the subject of a claim for extension of time or for excess costs or damages by the Contractor unless it is later determined that the Contractor was in compliance.
1.05 IMPLEMENTATION
A. Prior to commencement of the work, meet with the Engineer and Owner to develop mutual understandings relative to compliance with this provision and administration of the environmental pollution control program.
B. Remove temporary environmental control features, when approved by the Engineer, and incorporate permanent control features into the project at the earliest practicable time.
PART 2: PRODUCTS
A. Silt Fence
1. Silt fence shall meet the requirements of FDOT Design Standards for Design, Construction, Maintenance and Utility Operations on the State Highway System, latest edition, and Section 104 of the FDOT Standard Specifications for Road and Bridge Construction, latest edition.
B. One quarter inch woven wire mesh for filter boxes shall be galvanized steel or hardware cloth.
C. Straw mulch shall be utilized on all newly graded areas to protect areas against washouts and erosion. Straw mulch shall be comprised of threshed straw of oats, wheat, barley, or rye that is free from noxious weeds, mold or other objectionable material. The straw mulch shall contain at least 50 percent by weight of material to be 10-in or longer. Straw shall be in an air-dry condition and suitable for placement with blower equipment.
D. Latex acrylic copolymer, such as Soil Sealant with coalescing agent as manufactured by Soil Stabilization Co., Merced, CA or approved equivalent shall be used as straw mulch tackifier.
E. An asphalt tackifier shall only be used when temperatures are too low to allow the use of a latex acrylic copolymer and only with prior written approval from the Engineer.
F. Synthetic bales shall meet the requirements of FDOT Design Standards for Design, Construction, Maintenance and Utility Operations on the State Highway System, latest edition, and Section 104
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of the FDOT Standard Specifications for Road and Bridge Construction, latest edition. Synthetic bales shall be installed as shown in the design standards.
PART 3: EXECUTION
3.01 EROSION CONTROL
A. Provide positive means of erosion control such as shallow ditches around construction to carry off surface water. Erosion control measures, such as siltation basins, hay check dams, mulching, jute netting and other equivalent techniques, shall be used as appropriate. Flow of surface water into excavated areas shall be prevented. Ditches around construction area shall also be used to carry away water resulting from dewatering of excavated areas. At the completion of the work, ditches shall be backfilled and the ground surface restored to original condition.
3.02 PROTECTION OF STREAMS
A. Care shall be taken to prevent, or reduce to a minimum, any damage to any stream from pollution by debris, sediment or other material, or from the manipulation of equipment and/or materials in or near such streams. Water that has been used for washing or processing, or that contains oils or sediments that will reduce the quality of the water in the stream, shall not be directly returned to the stream. Such waters will be diverted through a settling basin or filter before being directed into the streams.
B. The Contractor shall not discharge water from dewatering operations directly into any live or intermittent stream, channel, wetlands, surface water or any storm sewer. Water from dewatering operations shall be treated by filtration, settling basins, or other approved method to reduce the amount of sediment contained in the water to allowable levels.
C. All preventative measures shall be taken to avoid spillage of petroleum products and other pollutants. In the event of any spillage, prompt remedial action shall be taken in accordance with a contingency action plan approved by the Florida Environmental Protection Division and the US EPA. The Contractor shall submit two copies of approved contingency plans to the Engineer. Depending on the nature of the spill, primary measures may include, but are not limited to:
1. Upon discovery, the Contractor shall contain the spill and keep the liquid from getting into streams, rivers, storm and sanitary sewers, drainage ditches, etc. Primary containment measures may include, but are not limited to:
a. Construction of a temporary containment berm utilizing absorbent pads, booms, or coils, and if necessary, native earth will be used.
b. Digging a sump, installing a polyethylene liner, and diverting the spilled material to the sump
c. Placing drums under the leak to collect the spilling material before if flows over on the ground.
d. Transferring the material from its original container to another container.
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2. All spills shall be cleaned up by the Contractor immediately, at no cost to the Owner. Contractor shall use absorbent materials for general clean up of liquids. If water is used, it must be collected and properly disposed of. Contactor shall clean or dispose of any equipment used to clean up the spill properly.
3. Materials and equipment necessary to spill cleanup shall be kept in the material storage areas. Typical materials and equipment includes, but is not limited to, brooms, dustpans, mops, rags, gloves, goggles, cat litter, sand, sawdust and properly labeled plastic and metal waste containers.
4. All spills shall be reported as required by local, State and Federal regulations.
a. For spills that impact surface water (leave a sheen on surface water), the National Response Center (NRC) shall be contacted within 24 hours at 1-800-424-8802.
b. For spills of an unknown amount, the National Response Center (NRC) shall be contacted within 24 hours at 1-800-424-8802.
c. For spills greater than 25 gallons and no surface water impacts, the Florida Environmental Protection Division shall be contacted within 24 hours.
d. For spills less than 25 gallons and no surface water impacts, the spill shall be cleaned up and local agencies shall be contacted as required.
5. The Contractor shall review spill prevention practices and procedures after a spill and adjust as necessary to prevent future spills.
6. The Contractor shall notify the Engineer and the Owner of the spill and the steps taken. If necessary, police, fire and medical personnel shall be notified as soon as possible for assistance.
7. The Contractor, the Engineer, and the Owner will conduct a joint inspection of the spill site to determine if the spill has been cleaned up to the satisfaction of the Owner. If the Owner requires the Contractor shall provide additional clean up at no additional cost to the Owner.
8. The Contractor shall keep the records of the measures taken and the material used to contain the spill. If absorbent material has been applied to soak up a spill, type and quantity of material shall be recorded.
D. Water being flushed from structures or pipelines after disinfection, with a Cl2 residue of 1 mg/l or greater shall be treated with a dechlorination solution, in a method approved by the Engineer, prior to discharging to sanitary sewer. No discharge to any storm sewer or natural water course will be allowed.
3.03 PROTECTION OF LAND RESOURCES
A. Land resources within the project boundaries and outside the limits of permanent work shall be restored to a condition, after completion of construction, which will appear to be natural and not detract from the appearance of the project. Confine all construction activities to areas shown on the Drawings.
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B. Outside of areas requiring earthwork for the construction of the new facilities, the Contractor shall not deface, injure, or destroy trees or shrubs, nor remove or cut them without prior approval. No ropes, cables, or guys shall be fastened to or attached to any existing nearby trees for anchorage unless specifically authorized by the Engineer. Where such special emergency use is permitted, first wrap the trunk with a sufficient thickness of burlap or rags over which softwood cleats shall be tied before any rope, cable, or wire is placed. The Contractor shall in any event be responsible for any damage resulting from such use.
C. Where trees may possibly be defaced, bruised, injured, or otherwise damaged by the Contractor's equipment, dumping or other operations, protect such trees by placing boards, planks, or poles around them. Monuments and markers shall be protected similarly before beginning operations near them.
D. Any trees or other landscape feature scarred or damaged by the Contractor's equipment or operations shall be restored as nearly as possible to its original condition. The Engineer will decide what method of restoration shall be used and whether damaged trees shall be treated and healed or removed and disposed of.
1. All scars made on trees by equipment, construction operations, or by the removal of limbs larger than 1-in in diameter shall be coated as soon as possible with an approved tree wound dressing. All trimming or pruning shall be performed in an approved manner by experienced workmen with saws or pruning shears. Tree trimming with axes will not be permitted.
2. Climbing ropes shall be used where necessary for safety. Trees that are to remain, either within or outside established clearing limits, that are subsequently damaged by the Contractor and are beyond saving in the opinion of the Engineer, shall be immediately removed and replaced.
E. The locations of the Contractor's storage, and other construction buildings, required temporarily in the performance of the work, shall be cleared portions of the job site or areas to be cleared and shall require written approval of the Engineer and shall not be within wetlands or floodplains. The preservation of the landscape shall be an imperative consideration in the selection of all sites and in the construction of buildings.
F. If the Contractor proposes to construct temporary roads or embankments and excavations for work areas, he/she shall submit the following for approval at least ten days prior to scheduled start of such temporary work.
1. A layout of all temporary roads, excavations and embankments to be constructed within the work area.
2. Details of temporary road construction.
3. Drawings and cross sections of proposed embankments and their foundations, including a description of proposed materials.
4. A landscaping drawing showing the proposed restoration of the area. Removal of any trees and shrubs outside the limits of existing clearing area shall be indicated. The drawing shall also indicate location of required guard posts or barriers required to control vehicular traffic
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passing close to trees and shrubs to be maintained undamaged. The drawing shall provide for the obliteration of construction scars as such and shall provide for a natural appearing final condition of the area. Modification of the Contractor's approved drawings shall be made only with the written approval of the Engineer. No unauthorized road construction, excavation or embankment construction including disposal areas will be permitted.
G. Remove all signs of temporary construction facilities such as haul roads, work areas, structures, foundations of temporary structures, stockpiles of excess of waste materials, or any other vestiges of construction as directed by the Engineer. It is anticipated that excavation, filling and plowing of roadways will be required to restore the area to near natural conditions which will permit the growth of vegetation thereon. The disturbed areas shall be prepared and seeded as described in Section 02930, or as approved by the Engineer.
H. All debris and excess material will be disposed of by this subcontractor outside wetland or floodplain areas in an environmentally sound manner.
3.04 PROTECTION OF AIR QUALITY
A. Burning. The use of burning at the project site for the disposal of refuse and debris will not be permitted.
B. Dust Control. The Contractor will be required to maintain all excavations, embankment, stockpiles, access roads, plant sites, waste areas, borrow areas, and all other work areas within or without the project boundaries free from dust which could cause the standards for air pollution to be exceeded, and which would cause a hazard or nuisance to others.
C. An approved method of stabilization consisting of sprinkling or other similar methods will be permitted to control dust. The use of petroleum products is prohibited. The use of chlorides may be permitted with approval from the Engineer.
D. Sprinkling, to be approved, must be repeated at such intervals as to keep all parts of the disturbed area at least damp at all times, and the Contractor must have sufficient competent equipment on the job to accomplish this if sprinkling is used. Dust control shall be performed as the work proceeds and whenever a dust nuisance or hazard occurs, as determined by the Engineer.
3.05 MAINTENANCE OF POLLUTION CONTROL FACILITIES DURING CONSTRUCTION
A. During the life of this Contract, maintain all facilities constructed for pollution control as long as the operations creating the particular pollutant are being carried out or until the material concerned has become stabilized to the extent that pollution is no longer being created.
3.06 NOISE CONTROL
A. The Contractor shall make every effort to minimize noises caused by his/her operations. Equipment shall be equipped with silencers or mufflers designed to operate with the least possible noise in compliance with State and Federal regulations.
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3.07 INSPECTION AND SAMPLING
A. All sediment and erosion control measures are to be adjusted to meet field conditions at the time of construction and be constructed prior to any grading or disturbance of existing surface material on balance of site. Sediment control structures will be inspected for integrity, any damaged devices shall be repaired immediately.
END OF SECTION
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SECTION 01200
PROJECT MEETINGS
PART 1 GENERAL
1.01 REQUIREMENTS INCLUDED
A. The Engineer shall schedule and administer pre-construction meeting, periodic progress meetings and specially called meetings throughout progress of the work.
1. Prepare agenda for meetings.
2. Make physical arrangements for meetings.
3. Preside at meetings.
4. Record the minutes; include significant proceedings and decisions.
5. Reproduce and distribute copies of minutes within 7 working days after each meeting.
a. To participants in the meeting.
b. To parties affected by decisions made at the meeting.
B. Representatives of contractors and suppliers attending meetings shall be qualified and authorized to act on behalf of the entity each represents.
C. Attend meetings to ascertain that work is expedited consistent with Contract Documents and construction schedules.
1.02 PRE-CONSTRUCTION MEETING
A. Schedule a preconstruction meeting no later than 7 days after date of Notice to Proceed.
B. Location: A central site, convenient for all parties, designated by the Owner.
C. Attendance
1. Lee County’s Representative.
2. Representative of Florida Governmental Utility Authority (FGUA)
3. CDM.
4. Contractor.
5. Major Subcontractors.
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6. Major suppliers.
7. Utilities
8. County Arborist
9. Others as appropriate.
D. Suggested Agenda
1. Distribution and discussion of:
a. List of major subcontractors and suppliers.
b. Projected Construction Schedules.
2. Critical work sequencing.
3. Major equipment deliveries and priorities.
4. Project Coordination.
a. Designation of responsible personnel.
5. Procedures and processing of:
a. Field decisions.
b. Proposal requests.
c. Submittals.
d. Change Orders.
e. Applications for Payment.
6. Adequacy of distribution of Contract Documents.
7. Procedures for maintaining Record Documents.
8. Use of premises:
a. Office, work and storage areas.
b. Owner's requirements.
9. Construction facilities, controls and construction aids.
10. Temporary utilities.
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11. Housekeeping procedures.
1.03 PROGRESS MEETINGS
A. Schedule regular periodic meetings. The progress meetings will be held every 14 days.
B. Hold called meetings as required by progress of the work.
C. Location of the meetings: Project field office of Contractor or Engineer.
D. Attendance
1. Engineer and his/her professional consultants as needed.
2. Contractor’s Superintendent
3. Subcontractors as appropriate to the agenda.
4. Suppliers as appropriate to the agenda.
5. Lee County’s representative.
6. FGUA's representative
7. Others as appropriate.
E. Suggested Agenda
1. Review, approval of minutes of previous meeting.
2. Review of work progress since previous meeting.
3. Field observations, problems and conflicts.
4. Problems which impede Construction Schedule.
5. Review of off-site fabrication, delivery schedules.
6. Corrective measures and procedures to regain projected schedule.
7. Revisions to Construction Schedule.
8. Progress, schedule, during succeeding work period.
9. Coordination of schedules.
10. Review submittal schedules; expedite as required.
11. Maintenance of quality standards.
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12. Pending changes and substitutions.
13. Review proposed changes for:
a. Effect on Construction Schedule and on completion date.
b. Effect on other contracts of the project.
14. Other business.
15. Construction schedule.
16. Critical/long lead items.
F. Attend progress meetings and is to study previous meeting minutes and current agenda items, in order to be prepared to discuss pertinent topics such as deliveries of materials and equipment, progress of the work, etc.
G. Provide a current submittal log at each progress meeting in accordance with Section 01300.
PART 2 PRODUCTS (NOT USED)
PART 3 EXECUTION (NOT USED)
END OF SECTION
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SECTION 01300
SUBMITTALS
PART 1 GENERAL
1.01 DESCRIPTION OF REQUIREMENTS
A. This Section specifies the general methods and requirements of submissions applicable to the following work-related submittals: Shop Drawings, Product Data, Construction Photographs, Construction or Submittal Schedules. Additional general submission requirements are contained in the General Conditions. Detailed submittal requirements will be specified in the technical specifications sections.
B. All submittals shall be clearly identified by reference to Specification Section, Paragraph, Drawing No. or Detail as applicable. Submittals shall be clear and legible and of sufficient size for sufficient presentation of data.
1.02 SHOP DRAWINGS, PRODUCT DATA
A. Shop Drawings
1. Shop drawings, as defined in the General Conditions, and as specified in individual work Sections include, but are not necessarily limited to, custom-prepared data such as fabrication and erection/installation drawings, scheduled information, setting diagrams, actual shopwork manufacturing instructions, custom templates, special wiring diagrams, coordination drawings, individual system or equipment inspection and test reports including performance curves and certifications, as applicable to the Work.
2. All shop drawings submitted by subcontractors for approval shall be sent directly to the Contractor for checking. The Contractor shall be responsible for their submission at the proper time so as to prevent delays in delivery of materials.
3. The Contractor shall check all subcontractor's shop drawings regarding measurements, size of members, materials, and details to satisfy himself that they conform to the intent of the Drawings and Specifications. Shop drawings found to be inaccurate or otherwise in error shall be returned to the subcontractors for correction before submission thereof.
4. All details on shop drawings submitted for approval shall show clearly the relation of the various parts to the main members and lines of the structure, and where correct fabrication of the work depends upon field measurements, such measurements shall be made by the Subcontractor and noted on the drawings before being submitted for approval.
B. Product Data
1. Product data as specified in individual Sections, include, but are not necessarily limited to, standard prepared data for manufactured products, such as the manufacturer's product specification and installation instructions, availability of colors and patterns, manufacturer's printed statements of compliances and applicability, roughing-in diagrams and templates,
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catalog cuts, product photographs, standard wiring diagrams, printed performance curves and operational-range diagrams, production or quality control inspection and test reports and certifications, mill reports, product operating and maintenance instructions and recommended spare-parts listing and printed product warranties, as applicable to the Work.
1.03 CONTRACTOR'S RESPONSIBILITIES
A. The Contractor shall review shop drawings and product data, including those by subcontractors, prior to submission to determine and verify the following:
1. Field measurements (elevations and locations)
2. Field construction criteria
3. Catalog numbers and similar data
4. Conformance with the Specifications
B. Each shop drawing, sample and product data submitted by the Contractor shall have affixed to it the following Certification Statement including the Contractor's Company name and signed by the Contractor:
"Certification Statement: by this submittal, I hereby represent that I have determined and verified all field measurements, field construction criteria, materials, dimensions, catalog numbers and similar data and I have checked and coordinated each item with other applicable approved shop drawings and all Contract requirements."
Shop drawings and product data sheets 11-in x 17-in and smaller shall be bound together in an orderly fashion and bear the above Certification Statement on the cover sheet. The cover sheet shall fully describe the packaged data and include a listing of all items within the package. Provide to the Engineer’s Representative a copy of each submittal transmittal sheet for shop drawings, product data and samples at the time of submittal of said drawings, product data and samples to the Engineer.
C. The Contractor shall utilize a 10-character submittal identification numbering system in the following manner:
1. The first character shall be a D, S, P, M, which represents Shop/Working Drawing and other Product Data (D), Sample (S), Preliminary Submittal (P), Operating/Maintenance Manual (M).
2. The next five digits shall be the applicable Specification Section Number.
3. The next three digits shall be the numbers 001-999 to sequentially number each initial separate item or drawing submitted under each specific Section number.
4. The last character shall be a letter, A-Z, indicating the submission, or resubmission of the same Drawing, i.e., "A=1st submission, B=2nd submission, C=3rd submission, etc. A typical submittal number would be as follows:
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D-03300-008-B
D = Shop Drawing
03300 = Specification Section for Concrete
008 = The eighth initial submittal under this specification section
B = The second submission (first resubmission) of that particular shop drawing
D. Notify the Engineer in writing, at the time of submittal, of any deviations in the submittals from the requirements of the Contract Documents.
E. The review and approval of shop drawings, samples or product data by the Engineer shall not relieve the Contractor from his/her responsibility with regard to the fulfillment of the terms of the Contract. All risks of error and omission are assumed by the Contractor and the Engineer will have no responsibility therefor.
F. No portion of the work requiring a shop drawing, sample, or product data shall be started nor shall any materials be fabricated or installed prior to the approval or qualified approval of such item. Fabrication performed, materials purchased or on-site construction accomplished which does not conform to approved shop drawings and data shall be at the Contractor's risk. The Owner will not be liable for any expense or delay due to corrections or remedies required to accomplish conformity.
G. Project work, materials, fabrication, and installation shall conform with approved shop drawings, applicable samples, and product data.
1.04 SUBMISSION REQUIREMENTS
A. Make submittals promptly in accordance with approved schedule, and in such sequence as to cause no delay in the Work or in the work of any other contractor.
B. Each submittal, appropriately coded, will be returned within 30 working days following receipt of submittal by the Engineer.
C. Number of submittals required:
1. Shop Drawings as defined in Paragraph 1.02 A: Six copies.
2. Product Data as defined in Paragraph 1.02 B: Six copies.
3. Samples: Submit the number stated in the respective Specification Sections.
D. Submittals shall contain:
1. The date of submission and the dates of any previous submissions.
2. The Project title and number.
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3. Contractor identification.
4. The names of:
a. Contractor
b. Supplier
c. Manufacturer
5. Identification of the product, with the specification section number, page and paragraph(s).
6. Field dimensions, clearly identified as such.
7. Relation to adjacent or critical features of the Work or materials.
8. Applicable standards, such as ASTM or Federal Specification numbers.
9. Identification of deviations from Contract Documents.
10. Identification of revisions on resubmittals.
11. A blank space suitably sized for Contractor and Engineer stamps.
12. Where calculations are required to be submitted by the CONTRACTOR, the calculations shall have been checked by a qualified individual other than the preparer. The submitted calculations shall clearly show the names of the preparer and of the checker.
1.05 REVIEW OF SHOP DRAWINGS, PRODUCT DATA, WORKING DRAWINGS AND SAMPLES
A. The review of shop drawings, data, and samples will be for general conformance with the design concept and Contract Documents. They shall not be construed:
1. as permitting any departure from the Contract requirements;
2. as relieving the Contractor of responsibility for any errors, including details, dimensions, and materials;
3. as approving departures from details furnished by the Engineer, except as otherwise provided herein.
B. The Contractor remains responsible for details and accuracy, for coordinating the work with all other associated work and trades, for selecting fabrication processes, for techniques of assembly, and for performing work in a safe manner.
C. If the shop drawings, data or samples as submitted describe variations and show a departure from the Contract requirements which Engineer finds to be in the interest of the Owner and to be so
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minor as not to involve a change in Contract Price or time for performance, the Engineer may return the reviewed drawings without noting an exception.
D. Submittals will be returned to the Contractor under one of the following codes.
Code 1 - "APPROVED" is assigned when there are no notations or comments on the submittal. When returned under this code the Contractor may release the equipment and/or material for manufacture.
Code 2 - "APPROVED AS NOTED". This code is assigned when a confirmation of the notations and comments IS NOT required by the Contractor. The Contractor may release the equipment or material for manufacture; however, all notations and comments must be incorporated into the final product.
Code 3 - "APPROVED AS NOTED/CONFIRM". This combination of codes is assigned when a confirmation of the notations and comments IS required by the Contractor. The Contractor may release the equipment or material for manufacture; however, all notations and comments must be incorporated into the final product. This confirmation shall specifically address each omission and nonconforming item that was noted. Confirmation is to be received by the Engineer within 15 calendar days of the date of the Engineer's transmittal requiring the confirmation.
Code 4 - "APPROVED AS NOTED/RESUBMIT". This combination of codes is assigned when notations and comments are extensive enough to require a resubmittal of the package. The Contractor may release the equipment or material for manufacture; however, all notations and comments must be incorporated into the final product. This resubmittal is to address all comments, omissions and non-conforming items that were noted. Resubmittal is to be received by the Engineer within 15 calendar days of the date of the Engineer's transmittal requiring the resubmittal.
Code 5 - "NOT APPROVED" is assigned when the submittal does not meet the intent of the Contract Documents. The Contractor must resubmit the entire package revised to bring the submittal into conformance. It may be necessary to resubmit using a different manufacturer/vendor to meet the Contract Documents.
Code 6 - "COMMENTS ATTACHED" is assigned where there are comments attached to the returned submittal which provide additional data to aid the Contractor.
Code 7 - "RECEIPT ACKNOWLEDGED" - This code is assigned to acknowledge receipt of a submittal that is not subject to the Engineer’s review and approval; and, is being filed for informational purposes only. This code is generally used in acknowledging receipt of means and methods of construction work plan, field conformance test reports, and Health and Safety plans.
Codes 1 through 5 designate the status of the reviewed submittal with Code 6 showing there has been an attachment of additional data.
E. Resubmittals will be handled in the same manner as first submittals. On resubmittals the Contractor shall direct specific attention, in writing on the letter of transmittal and on resubmitted shop drawings by use of revision triangles or other similar methods, to revisions other than the
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corrections requested by the Engineer, on previous submissions. Any such revisions which are not clearly identified shall be made at the risk of the Contractor. The Contractor shall make corrections to any work done because of this type revision that is not in accordance to the Contract Documents as may be required by the Engineer.
F. Partial submittals may not be reviewed. The Engineer will be the only judge as to the completeness of a submittal. Submittals not complete will be returned to the Contractor, and will be considered "Not Approved" until resubmitted. The Engineer may at his/her option provide a list or mark the submittal directing the Contractor to the areas that are incomplete.
G. Repetitive Review
1. Shop drawings and other submittals will be reviewed no more than twice at the Owner's expense. All subsequent reviews will be performed at times convenient to the Engineer and at the Subcontractor's expense, based on the Engineer's then prevailing rates. The Subcontractor shall reimburse the Owner for all such fees invoiced to the Owner by the Engineer. Submittals are required until approved.
2. Any need for more than one resubmission, or any other delay in obtaining Engineer's review of submittals, will not entitle Contractor to extension of the Contract Time.
H. If the Contractor considers any correction indicated on the shop drawings to constitute a change to the Contract Documents, the Contractor shall give written notice thereof to the Engineer at least seven working days prior to release for manufacture.
I. When the shop drawings have been completed to the satisfaction of the Engineer, the Contractor shall carry out the construction in accordance therewith and shall make no further changes therein except upon written instructions from the Engineer.
1.06 DISTRIBUTION
A. Distribute reproductions of approved shop drawings and copies of approved product data and samples, where required, to the job site file and elsewhere as directed by the Engineer. Number of copies shall be as directed by the Engineer but shall not exceed 6.
1.07 SCHEDULES
A. Provide all schedules required in the General Conditions.
B. While the Contractor bears full responsibility for scheduling all phases and stages of the work to insure its successful prosecution and completion within the time specified in accordance with all provisions of these Specifications, the Contractor is specifically required to complete fully or complete such stages of work to enable other trades to complete their work within the respective times specified.
1.08 PROFESSIONAL ENGINEER (P.E.) CERTIFICATION FORM
A. If specifically required in other Sections of these Specifications, the Contractor shall submit a P.E. Certification for each item required, in the form attached to this Section, completely filled in and stamped.
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1.09 GENERAL PROCEDURES FOR SUBMITTALS
A. Coordination of Submittal Times: Prepare and transmit each submittal sufficiently in advance of performing the related work or other applicable activities, or within the time specified in the individual work sections, of the Specifications, so that the installation will not be delayed by processing times including disapproval and resubmittal (if required), coordination with other submittals, testing, purchasing, fabrication, delivery and similar sequenced activities. No extension of time will be authorized because of the Contractor's failure to transmit submittals sufficiently in advance of the Work.
PART 2 PRODUCTS (Not Used)
PART 3 EXECUTION
3.01 SUBMITTAL SCHEDULE
A. Provide an initial submittal schedule register at the pre-construction meeting for review by Owner and Engineer. Incorporate comments from Owner or Engineer into a revised submittal schedule.
B. Maintain the submittal schedule and provide sufficient copies for review by Owner and Engineer. An up-to-date submittal schedule shall be provided at each project progress meeting.
3.02 TRANSMITTALS
A. Prepare separate transmittal sheets for each submittal. Each transmittal sheet shall include at least the following: the Contractor’s name and address, Owner’s name, project name, project number, submittal number, description of submittal and number of copies submitted.
B. Submittals shall be transmitted or delivered directly to the office of the Engineer, as indicated in the Contact Documents or as otherwise directed by the Engineer.
C. Provide copies of transmittals (only, i.e., without copies of the respective submittal) directly to the Resident Project Representative.
3.03 PROCEDURES
A. Contractor’s responsibilities
a. Coordination of Submittal Times: Prepare and transmit each submittal sufficiently in advance of performing the related work or other applicable activities, or within the time specified in the individual work of other related Sections, so that the installation will not be delayed by processing times including disapproval and resubmittal (if required). Coordinate with other submittals, testing, purchasing, fabrication, delivery and similar sequenced activities. Extensions to the Contract Time will not be approved for the Contractor’s failure to transmit submittals sufficiently in advance of the Work.
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b. The submittals of all shop drawings (including working drawings and product data) shall be sufficiently in advance of construction requirements to allow for possible need of re-submittals, including the specified review time for the Engineer.
c. Engineer’s review time for shop drawings and O&M manuals involving only one engineering discipline shall be no more than 21 calendar days. Engineer’s review time for shop drawings and O&M manuals that require review by more than one engineering discipline shall be no more than 28 calendar days. Resubmittals will be subject to the same review time.
d. Submittals of operation and maintenance data shall be provided within 30 days of approval of the related shop drawing(s).
e. Before submission to the Engineer, review shop drawings as follows:
1) make corrections and add field measurements, as required
2) use any color for its notations except red (reserved for the Engineer’s notations) and black (to be able to distinguish notations on black and white documents)
3) identify and describe each deviation or variation from Contract documents
4) include the required Contractor’s Certification statement
5) provide field measurements (as needed)
6) coordinate with other submittals
7) indicate relationships to other features of the Work
8) highlight information applicable to the Work and/or delete information not applicable to the Work
f. Submit the following number of copies:
1) Shop drawings (including working drawings and product data) – Submit no fewer than seven, and no more than nine; five of which will be retained by the Engineer.
2) Product Data – three copies
3) Samples – as stated in the representative Sections
4) Site Usage Plan – three copies
5) Schedule of values – four copies
6) Payment application format – four copies
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g. If Contractor considers any correction indicated on the shop drawings to constitute a change to the Contract Documents, provide written notice thereof to the Engineer immediately; and do not release for manufacture before such notice has been received by the Engineer.
h. When the shop drawings have been completed to the satisfaction of the Engineer, carry out the construction in accordance therewith; and make no further changes therein except upon written instructions from the Engineer.
B. Engineer’s Responsibilities
1. Engineer will not review shop drawings (including working drawings and product data) that do not include the Contractor's approval stamp. Such submittals will be returned to the Contractor, without action, for correction.
2. Partial shop drawings (including working drawings and product data) will not be reviewed. If, in the opinion of the Engineer, a submittal is incomplete, that submittal will be returned to the Contractor for completion. Such submittals may be returned with comments from Engineer indicating the deficiencies requiring correction.
3. If shop drawings (including working drawings and product data) meet the submittal requirements, Engineer will forward copies to appropriate reviewer(s). Otherwise, noncompliant submittals will be returned to the Contractor without action - with the Engineer retaining one copy.
4. Submittals which are transmitted in accordance with the specified requirements will be reviewed by the Engineer within the time specified herein. The time for review will commence upon receipt of submittal by Engineer.
END OF SECTION
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P.E. CERTIFICATION FORM
The undersigned hereby certifies that he/she is a Professional Engineer registered in the State of Florida and that he/she has been employed by
(Name of Contractor) ______to design ______in accordance with Specification Section ______for the
(Name of Project) ______.
The undersigned further certifies that he/she has performed the design of the
______, that said design is in conformance with all applicable local, state and federal codes, rules, and regulations, and that his/her signature and P.E. stamp have been affixed to all calculations and drawings used in, and resulting from, the design.
The undersigned hereby agrees to make all original design drawings and calculations available to the
(Insert Name of Owner)______or Owner's representative with seven days following written request therefor by the Owner.
______P.E. Name Contractor's Name
______Signature Signature
______Address Title
______Address
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SECTION 01370
SCHEDULE OF VALUES
PART 1 GENERAL
1.01 REQUIREMENTS INCLUDED
A. Submit a Schedule of Values allocated to the various portions of the work, within 14 days after the effective date of the Agreement.
B. Upon request of the Engineer, support the values with data which will substantiate their correctness.
C. The accepted Schedule of Values shall be used only as the basis for the Contractor's Applications for Payment.
1.02 RELATED REQUIREMENTS
A. Application for Payment is included in Section 01052.
1.03 FORM AND CONTENT OF SCHEDULE OF VALUES
A. Type schedule on an 8-1/2-in by 11-in or 8-1/2-in by 14-in white paper; Contractor's standard forms and automated printout will be considered for approval by the Engineer upon Contractor's request. Identify schedule with:
1. Title of Project and location.
2. Engineer and Project number.
3. Name and Address of Contractor.
4. Contract designation.
5. Date of submission.
B. Schedule shall list the installed value of the component parts of the work in sufficient detail to serve as a basis for computing values for progress payments during construction.
C. Identify each line item with the number and title of the respective major section of the specifications.
D. For each major line item list sub-values of major products or operations under the item.
E. For the various portions of the work:
1. Each item shall include a directly proportional amount of the Contractor's overhead and profit.
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2. For items on which progress payments will be requested for stored materials, break down the value into:
a. The cost of the materials, delivered and unloaded, with taxes paid. Paid invoices are required for materials upon request by the Engineer.
b. The total installed value.
F. The sum of all values listed in the schedule shall equal the total Contract Sum.
1.04 SUBSCHEDULE OF UNIT MATERIAL VALUES
A. Submit a sub-schedule of unit costs and quantities for:
1. Products on which progress payments will be requested for stored products.
B. The form of submittal shall parallel that of the Schedule of Values, with each item identified the same as the line item in the Schedule of Values.
C. The unit quantity for bulk materials shall include an allowance for normal waste.
D. The unit values for the materials shall be broken down into:
1. Cost of the material, delivered and unloaded at the site, with taxes paid.
2. Copies of invoices for component material shall be included with the payment request in which the material first appears.
3. Paid invoices shall be provided with the second payment request in which the material appears or no payment shall be allowed and/or may be deleted from the request.
E. The installed unit value multiplied by the quantity listed shall equal the cost of that item in the Schedule of Values.
PART 2 PRODUCTS (NOT USED)
PART 3 EXECUTION (NOT USED)
END OF SECTION
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SECTION 01390
CONSTRUCTION PHOTOGRAPHS
PART 1 GENERAL
1.01 REQUIREMENTS INCLUDED
A. Contractor shall provide competent photographer to take construction record photographs periodically during course of the Work.
1.02 PHOTOGRAPHY REQUIRED
A. A preconstruction video is required to be taken prior to the start of construction. The preconstruction video is required to document the existing structures, equipment, existing site conditions and the existing conditions of the landscape buffer zone to establish a baseline for restoration work as required. The preconstruction video will be on digital video disc (DVD) format and will provide the date and time of the video on the disc during playback.
1.03 COSTS OF PHOTOGRAPHY
A. The Contractor shall pay costs for specified photography and disk copies.
PART 2 PRODUCTS
2.01 VIDEO TAPE / DISC
A. Audio-visual disc for color video recorder. Camera shall be capable of minimum 8:1 zoom, have low light capability, be battery powered, show transparent date and time, and produce clean transitions from one scene to another.
B. Label each DVD and corresponding case with the following information:
1. Name of project and bid number
2. Tape number
3. Orientation of view
4. Time and date of taping
5. Name and address of operator
6. Contractor’s name
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PART 3 EXECUTION
3.01 TECHNIQUE
A. Factual presentation
B. Correct exposure and focus
1. High resolution and sharpness
2. Maximum depth-of-field
3. Minimum distortion
3.02 VIEWS REQUIRED
A. Photograph from location to adequately illustrate condition of construction.
1. Views for pre-construction and post-construction shall cover the same areas. Each view shall show the time and date when was taken.
3.03 DELIVERY OF PRINTS
A. Distribution of prints as soon as processed is anticipated to be as follows:
1. Engineer (one disk)
2. Owner (one disk)
3. Project Record File (one set to be stored by Contractor). At the end of the project, Owner shall receive this set.
C. No construction shall start until preconstruction video are completed and submitted to the Engineer.
3.04 AUDIOVISUAL RECORDING
A. The recordings shall contain coverage of all surface features within the construction zone of influence. These features shall include, but not be limited to, all roadways, pavement, wheelchair ramps, traffic separators, parking spaces, curbs, driveways, sidewalks, culverts, headwalls, retaining walls, landscaping, trees, and fences. Of particular concern shall be the existence or non-existence of any faults, fractures or defects.
B. Video coverage shall be limited to one side of the street at one time and shall include all surface conditions located within the zone of influence supported by appropriate audio description. Panning, zoom-in and zoom-out rates shall be sufficiently controlled to maintain a clear view of the object.
C. Accompanying the video recording of each video tape shall be a corresponding and simultaneously recorded audio recording. This audio recording, exclusively containing the commentary of the camera operator, shall assist in viewer orientation and in any needed identification, differentiation, clarification, or objective description of the features being shown
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in the video portion of the recording. The audio recording shall also be free from any conversation between the camera operator and any other production technicians.
D. Visibility: All recording shall be performed during times of good visibility; no recording shall be done during periods of significant precipitation, mist or fog. The recording shall only be done when sufficient sunlight is present to properly illuminate the subject and to produce sharp, bright video recordings of those subjects.
E. In order to ensure the continuity of coverage, the coverage shall consist of a single continuous unedited recording which begins at one end of the construction area.
F. The average rate of travel during a particular segment of coverage shall be directly proportional to the number, size, and value of the surface features within that construction area’s zone of influence.
G. Camera Operation
1 Camera Height and Stability: When conventional wheeled vehicles are used as conveyances for the recording system, the vertical distance between the camera lens and the ground shall not exceed 10 feet. The camera shall be firmly mounted such that transport of the camera during the recording process will not cause an unsteady picture.
2 Camera Control: Camera pan, tilt, zoom-in and zoom-out rates shall be sufficiently controlled such that recorded objects shall be clearly viewed during video tape playback. In addition, all other camera and recording system controls, such as lens focus and aperture, video level, pedestal, white balance and electrical focus shall be properly controlled or adjusted to maximize picture quality.
3 Viewer Orientation Techniques: The audio and video portions of the recording shall maintain viewer orientation. To this end, overall establishing views of all visible house and business addresses shall be utilized. In areas where the proposed construction location will not be readily apparent to the video tape viewer, highly visible yellow flags shall be placed, by the Contractor, in such a fashion as to clearly indicate the proposed center line of construction.
END OF SECTION
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SECTION 01410
TESTING AND TESTING LABORATORY SERVICES
PART 1: GENERAL
1.01 REQUIREMENTS INCLUDED
A. Contractor shall employ and pay for the services of an Independent Testing Laboratory approved by the Owner to perform testing.
1. Subcontractor shall cooperate with the laboratory to facilitate the execution of its required services.
2. Employment of the laboratory shall in no way relieve Contractor’s obligations to perform the Work of the Contract.
3. Payment for passing tests will be made to the Subcontractor by the Owner. The Subcontractor shall submit receipts for testing in his pay request. The Subcontractor shall pay for the failing tests.
1.02 RELATED REQUIREMENTS
A. Conditions of the Contract: Inspections and testing required by laws, ordinances, rules, regulations, orders or approvals of public authorities.
B. Respective sections of specifications: Certification of products.
C. Each specification section listed: Laboratory tests required and standards for testing.
D. Testing Laboratory inspection, sampling and testing is required for but not limited to the following:
1. Site Preparation is included in Section 02100.
2. Trenching, backfilling, and compaction is included in Section 02221.
3. Hot-mixed Asphalt Paving is included in Section 02513.
4. Concrete is included in Section 03300.
1.03 LIMITATIONS OF AUTHORITY OF TESTING LABORATORY
A. Laboratory is not authorized to:
1. Release, revoke, alter or enlarge on requirements of Contract Documents.
2. Approve or accept any portion of the Work. 3. Perform any duties of the Subcontractor.
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1.04 SUBCONTRACTOR'S RESPONSIBILITIES
A. Cooperate with laboratory personnel, provide access to work, to manufacturer's operations.
B. Secure and deliver to the laboratory adequate quantities of representative samples of materials proposed to be used and which require testing.
C. Provide to the laboratory the preliminary design mix proposed to be used for concrete and other materials mixes which require control by the testing laboratory.
D. Materials and equipment used in the performance of work under this Contract are subject to inspection and testing at the point of manufacture or fabrication. Standard specifications for quality and workmanship are indicated in the Contract Documents. The Engineer may require the Equipment Supplier or the Subcontractor to provide statements or certificates from the manufacturers and fabricators that the materials and equipment provided by them are manufactured or fabricated in full accordance with the standard specifications for quality and workmanship indicated in the Contract Documents. All costs of this testing and providing statements and certificates shall be a subsidiary obligation of the Subcontractor, and no extra charge to the Owner shall be allowed on account of such testing and certification.
E. Furnish incidental labor and facilities:
1. To provide access to work to be tested.
2. To obtain and handle samples at the Project site or at the source of the product to be tested.
3. To facilitate inspections and tests.
4. For storage and curing of test samples.
F. Notify laboratory sufficiently in advance of operations to allow for laboratory assignment of personnel and scheduling of tests.
G. Employ and pay for the services of the same or a separate, equally qualified independent testing laboratory to perform additional inspections, sampling and testing required for the Subcontractor's convenience.
H. If the test results indicate the material or equipment complies with the Contract Documents, the Subcontractor shall pay for the cost of the testing laboratory. If the tests and any subsequent retests indicate the materials and equipment fail to meet the requirements of the Contract Documents, the Subcontractor may pay for the laboratory costs directly to the testing firm or the total of such costs shall be deducted from any payments due the Contractor.
PART 2: PRODUCTS (Not Used)
PART 3: EXECUTION (Not Used)
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END OF SECTION
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SECTION 01445
PIPELINE TESTING AND CLEANING
PART 1: SCOPE
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required to test and clean all new pipelines installed under this Contract as specified herein.
1.02 RELATED WORK
A. Buried pipelines are included in Division 2.
PART 2: PRODUCTS (NOT USED)
PART 3: EXECUTION
3.01 GENERAL
A. Furnish all necessary equipment and labor for cleaning and testing the pipelines. The procedures and methods shall be approved by the Engineer.
B. Make any taps and furnish all necessary caps, plugs, etc., as required in conjunction with testing pipelines. Furnish a test pump, gages and any other equipment required in conjunction with carrying out the hydrostatic tests.
3.02 CLEANING PIPELINES
A. Contractor shall take all the precautions to keep the interior of the pipes free of debris before and after the installation. When the construction is ceased for any reason, installed pipes shall be capped to prevent entrance of any dirt or animal.
B. As pipe laying progresses and at the conclusion of the work thoroughly clean all new pipelines by flushing with water or other means to remove all dirt, stones, pieces of wood or other material which may have entered during the construction period. If, after this cleaning, obstructions remain, they shall be removed.
C. Because of the size of the finished force main, the Contractor shall expect that the cleaning may be done when a certain amount of pipe is installed and ready for pressure/leakage testing. The minimum length requirement will be decided by the Contractor and Engineer during the preconstruction meeting. A section of main will be considered ready for testing after completion of all thrust restraint and backfilling. The Contractor shall submit the cleaning procedure for Engineer’s review at least 10 days before starting the cleaning of the first section.
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D. When a section of pipe is ready for pressure/leakage test, thoroughly clean the entire pipe by flushing with water or other means to remove all dirt, stones, pieces of wood, or other material which may have entered during the construction period. All debris shall be removed from the pipeline. The lowest segment outlet shall be flushed last to assure debris removal. Flow velocity shall be greater than 4 feet per second to adequately remove debris from pipe and valve seats. The Contractor shall partially operate valves and hydrants to clean out seats.
E. Temporary blow-offs shall be installed for the purpose of clearing the force main. Blow-offs installed on force mains up to and including 12 inches shall be the same diameter as the force main. Pipes shall be flushed at blow off points and at dead ends to achieve a minimum flow velocity specified in Paragraph C above, and a minimum of 3 turnovers of treated water shall be used in the flushing operation. Blow-offs installed on 16 inch force mains and larger shall be the next smaller size, in diameter, than the force main being tested. Temporary blow-offs shall be removed and plugged after the main is cleared.
F. After the pipe lines are cleaned and if the ground-water level is above the pipe, or following a heavy rain, the Engineer will examine the pipe for leaks. If defective pipes or joints are discovered at this time, they shall be repaired or replaced by the Contractor.
G. The Contractor shall be responsible for the proper disposal or discharge of the water during the flushing operation. The Contractor shall be responsible for repairing all damages due to the flushing operation at no cost to the Owner.
3.03 TESTING PRESSURE PIPELINES
A. All pressure pipelines shall be pressure and leakage tested. Pipelines shall be tested in sections, valve to valve or 3,000 feet whichever distance is smaller. The pressure and leakage tests shall be conducted at 150 PSI or 2.5 times the operating pressure, whichever is greater, measured at the lowest point for at least two (2) hours. The test pump and water supply shall be arranged to allow accurate measurement of the water required to maintain the test pressure. Any water added will be considered leakage. Allowable leakage shall be in accordance with the latest edition of the AWWA C600.
3.04 DISINFECTING PIPELINES (For potable water service only if repair/relocating required)
A. After successful pressure testing of each pipeline section, disinfect in accordance with the latest edition of AWWA C651 for the continuous feed method. The Contractor shall submit a written procedure for Engineer’s approval before being permitted to proceed with the disinfection.
B. Following the chlorination, all treated water shall be flushed from the lines at their extremities and replaced with potable water. All treated water flushed from the lines shall be disposed of by discharging to the nearest sanitary sewer or by other approved means. Bacteriological sampling and analysis of the replacement water may then be made. Lee County Utilities personnel shall collect samples from the line and test for bacteriological quality in accordance with the rules of the Lee County Public Health Department, Environmental Protection Division and in full accordance with AWWA C651. At least one set of samples shall be collected at every 1,200 feet, plus one set from the end of the line and at least one set from each branch and dead-end. The line shall be rechlorinated, if necessary and the line shall not be placed in service until the requirements of the County Public Health Department are met.
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C. After Engineer’s approval, special disinfecting procedures shall be used in connections to existing pipelines and where the method outlined above is not practical.
D. The bacteriological samples shall be analyzed for both coliform and non-coliform growth. Testing shall be performed by a laboratory certified by the State of Florida. Lee County Utilities has its own laboratory (which is certified by the State) to test bacteriological quality.
END OF SECTION
5000-79695 01445-3 Florida Governmental Utility Authority Waterway Estates Interconnect 60% Submittal
SECTION 01520
CONSTRUCTION AIDS
PART 1: GENERAL
1.01 REQUIREMENTS INCLUDED
A. Furnish, install and maintain required construction aids, remove on completion of Work.
1.02 RELATED REQUIREMENTS
A. Summary of Work is included in Section 01010.
PART 2: PRODUCTS
2.01 MATERIALS
A. Materials may be new or used, suitable for the intended purpose, but must not violate requirements of applicable codes and standards.
2.02 CONSTRUCTION AIDS
A. Provide construction aids and equipment required by personnel and to facilitate execution of the Work; Scaffolds, staging, ladders, stairs, ramps, runways, platforms, railings, hoists, cranes, chutes and other such facilities and equipment.
1. Refer to respective sections for particular requirements for each trade.
B. When permanent stair framing is in place, provide temporary treads, platforms and railings, for use by construction personnel.
C. Maintain facilities and equipment in first-class condition.
2.03 TEMPORARY ENCLOSURES
A. Provide temporary weather-tight enclosure of exterior walls for successive areas of building as work progresses, as necessary to provide acceptable working conditions, provide weather protection for materials, allow for effective temporary heating and to prevent entry of unauthorized persons.
1. Provide temporary exterior doors with self-closing hardware and padlocks.
2. Other enclosures shall be removable as necessary for work and for handling of materials.
PART 3: EXECUTION
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3.01 PREPARATION
A. Consult with the Engineer, review site conditions and factors which affect construction procedures and construction aids, including adjacent properties and public facilities which may be affected by execution of the Work.
3.02 GENERAL
A. Comply with applicable requirements specified in sections of Divisions 2 through 16.
B. Relocate construction aids as required by progress of construction, by storage or work requirements and to accommodate legitimate requirements of Owner and other Contractors employed at the site.
3.03 REMOVAL
A. Completely remove temporary materials, equipment and services:
1. When construction needs can be met by use of permanent construction.
2. At completion of work.
B. Clean and repair damage caused by installation of or by use of temporary facilities.
1. Remove foundations and underground installations for construction aids.
2. Grade areas of site affected by temporary installations to required elevations and slopes and clean the area.
C. Restore permanent facilities used for temporary purposes to specified condition or in kind if not specified.
END OF SECTION
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SECTION 01540
SECURITY
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall ensure that each employee, representative, Supplier, and others acting for the Contractor use designated access roads and parking areas.
B. The Contractor shall employ watchmen on the work when necessary and shall erect and maintain additional such strong and suitable barriers and such lights as shall effectually prevent the happening of any accident to health or to property or to any partially completed work or to any materials stored on or adjacent to the site of the work.
C. The Contractor shall employ any additional temporary fencing and gates to adequately protect the work, and shall provide all access required by the Engineer and the Owner.
D. Stored materials shall be kept in a neat and orderly manner. Materials that are subject to deteriorations by exposure to the sun, rain or other elements shall be kept adequately covered and protected.
E. The Contractor shall be responsible for protecting all stored materials and the project site safe from theft and vandalism. The Contractor shall employ security personnel and erect, throughout the ROW and public thoroughfares and roads, additional fences as necessary at no additional cost to the Owner.
PART 2 – MATERIALS (NOT USED)
PART 3 – EXECUTION (NOT USED)
END OF SECTION
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SECTION 01580
PROJECT IDENTIFICATION AND SIGNS
PART 1 GENERAL
1.01 REQUIREMENTS
A. Furnish, install and maintain informational signs.
B. Remove signs on completion of construction.
C. Allow no other signs to be displayed.
1.02 SUBMITTALS
A. Submit in accordance with the requirements of Section 01300.
1.03 PROJECT IDENTIFICATION SIGN
A. Four professionally prepared, painted signs, of not less than 32 square feet area, with printed graphic content to include:
1. Title of project
2. Name of Owner
3. Names and titles of authorities
4. Name and title of Engineer
5. Prime Contractor
6. Major Contractors
B. Graphic design, style of lettering and colors: as approved by the Engineer and meeting applicable local regulations for signs.
C. Erect on the site at lighted locations of high public visibility as approved by the Engineer.
1.04 INFORMATIONAL SIGNS [NOT USED]
1.05 QUALITY ASSURANCE
A. Sign Painter: Professional Experience in type of work required.
B. Finishes, Painting: Adequate to resist weathering and fading for scheduled construction period.
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PART 2 PRODUCTS
2.01 SIGN MATERIALS
A. Structure and Framing: May be new or used, wood or metal, in sound condition structurally adequate to work and suitable for specified finish.
B. Sign Surfaces: Exterior softwood plywood with medium density overlay, standard large sizes to minimize joints.
1. Thickness: As required by standards to span framing members, to provide even, smooth surface without waves or buckles.
C. Rough Hardware: Galvanized
D. Paint: Exterior quality.
1. Use Bulletin colors for graphics.
2. Colors for structure, framing, sign surfaces and graphics: As selected by the Owner.
PART 3 EXECUTION
3.01 PROJECT INFORMATIONAL SIGN
A. Paint exposed surfaces of supports, framing and surface material; one coat of primer and one coat of exterior paint.
B. Paint graphics in styles, sizes and colors selected.
3.02 MAINTENANCE
A. Maintain signs and supports in a neat, clean condition; repair damages to structure, framing or sign.
3.03 REMOVAL
A. Remove signs, framing, supports and foundations at completion of project.
END OF SECTION
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SECTION 01600
DELIVERY, STORAGE AND HANDLING
PART 1 GENERAL
1.01 SCOPE OF WORK
A. This Section specifies the general requirements for the delivery handling, storage and protection for all items required in the construction of the work. Specific requirements, if any, are specified with the related item.
1.02 TRANSPORTATION AND DELIVERY
A. Transport and handle items in accordance with manufacturer's instructions.
B. Coordinate delivery with installation to ensure minimum holding time for items that are hazardous, flammable, easily damaged or sensitive to deterioration.
C. Deliver products to the site in manufacturer's original sealed containers or other packing systems, complete with instructions for handling, storing, unpacking, protecting and installing.
D. All items delivered to the site shall be unloaded and placed in a manner which will not hamper the Contractor's normal construction operation or those of subcontractors and other contractors and will not interfere with the flow of necessary traffic.
E. Provide necessary equipment and personnel to unload all items delivered to the site.
F. Promptly inspect shipment to assure that products comply with requirements, quantities are correct, and items are undamaged. For items furnished by others (i.e. Owner, other Contractors), perform inspection in the presence of the Engineer. Notify Engineer verbally, and in writing, of any problems.
1.03 STORAGE AND PROTECTION
A. Store and protect products in accordance with the manufacturer's instructions, with seals and labels intact and legible. Storage instruction shall be studied by the Contractor and reviewed with the engineer by him/her. Instruction shall be carefully followed and a written record of this kept by the Contractor. Arrange storage to permit access for inspection.
B. Store loose granular materials on solid flat surfaces in a well-drained area. Prevent mixing with foreign matter.
C. Cement and lime shall be stored under a roof and off the ground and shall be kept completely dry at all times. All structural, miscellaneous and reinforcing steel shall be stored off the ground or otherwise to prevent accumulations of dirt or grease, and in a position to prevent accumulations of standing water and to minimize rusting. Beams shall be stored with the webs vertical. Precast concrete shall be handled and stored in a manner to prevent accumulations of dirt, standing water,
5000-79695 01600-1 Florida Governmental Utility Authority Waterway Estates Interconnect 60% Submittal
staining, chipping or cracking. Brick, block and similar masonry products shall be handled and stored in a manner to reduce breakage, cracking and spalling to a minimum.
D. All mechanical and electrical equipment and instruments subject to corrosive damage by the atmosphere if stored outdoors (even though covered by canvas) shall be stored in a weathertight building to prevent injury. The building may be a temporary structure on the site or elsewhere, but it must be satisfactory to the Engineer. Building shall be provided with adequate ventilation to prevent condensation. Maintain temperature and humidity within range required by manufacturer.
1. All equipment shall be stored fully lubricated with oil, grease and other lubricants unless otherwise instructed by the manufacturer.
2. Moving parts shall be rotated a minimum of once weekly to insure proper lubrication and to avoid metal-to-metal "welding". Upon installation of the equipment, the Contractor shall start the equipment, at least half load, once weekly for an adequate period of time to ensure that the equipment does not deteriorate from lack of use.
3. Lubricants shall be changed upon completion of installation and as frequently as required thereafter during the period between installation and acceptance. New lubricants shall be put into the equipment at the time of acceptance.
4. Prior to acceptance of the equipment, the Contractor shall have the manufacturer inspect the equipment and certify that its condition has not been detrimentally affected by the long storage period. Such certifications by the manufacturer shall be deemed to mean that the equipment is judged by the manufacturer to be in a condition equal to that of equipment that has been shipped, installed, tested and accepted in a minimum time period. As such, the manufacturer will guaranty the equipment equally in both instances. If such a certification is not given, the equipment shall be judged to be defective. It shall be removed and replaced at the Contractor's expense.
5. Special attention shall be paid to the staging, storage, utilization, and disposal of all chemical products necessary to carry our HDD & Jack and Bores (J&B), including but not limited to, proper disposal. The Subcontractor shall submit a work plan prior to drilling on J&B activities that will address storage, handling and disposal of the chemicals. The Contractor shall include all these means, methods and materials in their base price.
PART 2: PRODUCTS (Not Used)
PART 3: EXECUTION (Not Used)
END OF SECTION
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SECTION 01660
PRESSURE TESTING
PART 1 GENERAL
1.01 DESCRIPTION OF REQUIREMENTS
A. The Contractor shall be responsible for the pressure testing of all systems prior to placing them in service.
B. The pressure testing shall be as required to prove that the piping is left in proper condition for satisfactory operation under the conditions specified.
C. All force mains will be pressure tested to potable water main standards.
D. Operation of existing facilities: conduct all test in a manner to minimize, as much as possible, any interference with the day-to-day operations of existing facilities or other contractors working the site.
1.02 PERFORMANCE REQUIREMENTS
A. Written Notification of Testing: Provide written notice when the work is ready for testing, and make the tests as soon thereafter as possible.
1. Personnel for reading meters, gauges, or other measuring devices will be furnished.
2. Furnish all other labor, equipment, air, water and materials, including meters, gauges, smoke producers, blower, pumps, compressors, fuel, water, bulkheads and accessory equipment.
1.03 REFERENCES
A. Codes and standards referred to in this Section are:
1. AWWA C-600 – Installation of Ductile-Iron Water Mains and Their Appurtenances.
1.04 SUBMITTALS
A. General: Provide all submittals, including the following, as specified in Division 1.
B. Testing Report: Prior to placing the sewer system in service, submit for review and approval a detailed bound report summarizing the leakage test data, describing the test procedure and showing the calculations on which the leakage test data is based.
PART 2 MATERIALS AND EQUIPMENT (NOT USED)
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PART 3 EXECUTION
3.01 PRESSURE AND LEAKAGE TESTS
A. Tests shall be conducted in the presence of and to the satisfaction of the Engineer and the Owner and of the authorities having jurisdiction over the work. Notice shall be given prior to start of test.
1. Flushing
a. All mains shall be flushed to remove all sand and other foreign matter. The velocity of the flushing water shall be at least 4 fps. Flushing shall be terminated at the direction of the Engineer. Dispose of the flushing water without causing a nuisance or property damage.
b. Temporary flush out connections shall be installed on all dead end water mains at the locations shown on the Drawings and in accordance with the detail shown in Section 9 of the Lee County Utilities Operations Manual.
2. Hydrostatic Testing
Perform hydrostatic testing on the system as set forth in the following, and shall conduct said tests in the presence of representatives from the County and other authorized agencies, with 48 hours advance notice provided.
B. Subcontractor shall be responsible for securing permission to use Lee County supplied water for all testing. If Subcontractor cannot secure permission from Lee County, he shall be responsible for supplying all water necessary to accomplish testing.
C. Field pressure and leakage test. This test measures the amount of water required to be supplied to newly laid pipe to maintain a specific pressure after the pipe has been filled with water and the air expelled. The duration of this test shall be not less than two hours and the test pressure shall be 2.5 times the operating pressure or 150 psig, whichever is greater, as measured at the lowest point in the line. The maximum allowable leakage shall not exceed the limits specified below or the Lee County Utilities standard specifications, whichever is smaller.
D. Piping and appurtenances to be tested shall be within sections between valves unless alternate methods have received prior approval from the County. Testing shall not proceed until concrete thrust blocks are in place and cured, or other restraining devices installed. All piping shall be thoroughly cleaned and flushed prior to testing to clear the lines of all foreign matter. While the piping is being filled with water, care shall be exercised to permit the escape of air from extremities of the test section, with additional release cocks provided if required.
E. The testing procedure shall include the continued application of the specified pressure to the test system, for the one hour period, by way of a pump taking supply from a container suitable for measuring water loss. The amount of loss shall be determined by measuring the volume displaced from said container.
F. Should the test fail, necessary repairs shall be accomplished by the Contractor and the test repeated until results are within the established limits. The Contractor shall furnish the necessary labor, water, pumps, and gauges at specified location(s) and all other items required to conduct the required testing and perform necessary repairs.
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MAXIMUM QUANTITY OF WATER (GALLONS PER HOUR) THAT MAY BE SUPPLIED TO MAINTAIN PRESSURE WITHIN 5 P.S.I. OF THE SPECIFIED TEST PRESSURE (MECHANICAL OR PUSH-ON JOINT, 18 FT NOMINAL LENGTHS, PER 1000 FT OF PIPE)
PIPE DIAMETER (INCHES) Average Test 3 4 6 8 10 12 14 16 18 20 24 30 36 Pressure (psi) 450 0.43 0.57 0.86 1.15 1.43 1.72 2.01 2.29 2.58 2.87 3.44 4.3 5.16 400 0.41 0.54 0.81 1.08 1.35 1.62 1.89 2.16 2.43 2.7 3.24 4.05 4.86 350 0.38 0.51 0.76 1.01 1.26 1.52 1.77 2.02 2.28 2.53 3.03 3.79 4.55 300 0.35 0.47 0.7 0.94 1.17 1.4 1.64 1.87 2.11 2.34 2.81 3.51 4.21 275 0.34 0.45 0.67 0.9 1.12 1.34 1.57 1.79 2.02 2.24 2.69 3.36 4.03 250 0.32 0.43 0.64 0.85 1.07 1.28 1.5 1.71 1.92 2.14 2.56 3.21 3.85 225 0.3 0.41 0.61 0.81 1.01 1.22 1.42 1.62 1.82 2.03 2.43 3.04 3.65 200 0.29 0.38 0.57 0.76 0.96 1.15 1.34 1.53 1.72 1.91 2.29 2.87 3.44 175 0.27 0.36 0.54 0.72 0.89 1.07 1.25 1.43 1.61 1.79 2.15 2.68 3.22 150 0.25 0.33 0.5 0.66 0.83 0.99 1.16 1.32 1.49 1.66 1.99 2.48 2.98 125 0.23 0.3 0.45 0.6 0.76 0.91 1.06 1.21 1.36 1.51 1.81 2.27 2.72 100 0.2 0.27 0.41 0.54 0.68 0.81 0.95 1.08 1.22 1.35 1.62 2.03 2.43
NOTES: 1 To obtain the maximum quantity of water for pipe with 20 ft Nominal lengths, multiply the quantity calculated from the table by 0.9 2 The maximum quantity of added water for a pipeline is calculated by multiplying the quantity per hour as obtained from the above table by the duration of the test in hours and by the total length of the line being tested divided by 1000. If the line under test contains sections of various diameters, the maximum quantity added will be the sum of the computed quantities for each size. 3 Maximum test length = 3,000 feet per section This standard shall reflect any revision of A.W.W.A. C-600, however, the maximum quantity of water added shall not exceed 50% of the 4 recommended limit per applicable A.W.W.A. C-600 standard. 5 Standard test pressure = 150p.s.i. 6 Formula basis: L = (S) x (D) x (P)1/2 148,000
L = Maximum quantity of water to be added (gallons per hour) S = Length of pipe tested (feet) D = Diameter of pipe (inches) P = Test pressure (p.s.i.) 7 Pressure test duration to be min. 2 hours
END OF SECTION
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SECTION 01700
CONTRACT CLOSEOUT
PART 1 GENERAL
1.01 SCOPE OF WORK
A. This Section specifies administrative and procedural requirements for project closeout, including but not limited to:
1. Closeout procedures.
2. Final cleaning.
3. Adjusting.
4. Project as built documents.
5. Spare parts and maintenance materials.
1.02 RELATED WORK
A. Warranties and Bonds are included in Section 01740.
1.03 RECORD DOCUMENTS
A. Maintain on site, one set of the following documents; actual revisions to the work shall be recorded in these documents:
1. Contract Drawings.
2. Specifications.
3. Addenda.
4. Change Orders and other Modifications to the Contract.
5. Reviewed shop drawings, product data, and samples.
B. Store As Built Documents separate from documents used for construction.
C. Record information concurrent with construction progress.
D. Specifications: Legibly mark and record at each Product section description of actual products installed, including the following:
1. Manufacturer's name and product model and number.
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2. Product substitutions or alternates utilized.
3. Changes made by Addenda and Modifications.
E. Contract Drawings and Shop Drawings: Legibly mark each item to record actual construction including:
1. Measured depths of structures in relation to NGVD 1929 datum.
2. Measured horizontal and vertical locations of underground utilities and appurtenances, referenced to permanent surface improvements.
3. Measured locations of internal utilities and appurtenances concealed in construction, referenced to visible and accessible features of the work.
4. Field changes of dimension and detail.
5. Details not on original Contract Drawings.
F. Submit documents (CAD and hard copies) to Engineer with Application for Final Payment. Electronic copies of “As-Builts” shall be AutoCAD 2000 or newer version. Electronic format shall match reproducible set. All existing features located on construction plans shall be shown on as-builts.
G. The front cover of the As Built Drawings shall contain the following information:
1. Date of As Built Drawings
2. Project title and bid number
3. Contractor’s name and address
4. Signature of Contractor or authorized representative
1.04 CLOSEOUT PROCEDURES
A. Submit written certification that Contract Documents have been reviewed, work has been inspected and that work is complete in accordance with Contract Documents and ready for Engineer's inspection.
B. Engineer shall make inspection with reasonable promptness. If Work is incomplete or defective, Engineer shall notify Contractor to remedy deficiencies.
C. Upon renotification of completion, Engineer shall reinspect Work, and when acceptable, issue Certificate of Substantial Completion.
D. Provide submittals to Owner that are required by governing or other authorities.
E. Submit Application for Final Payment identifying total adjusted Contract Sum, previous payments and sum remaining due.
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1.05 FINAL CLEANING
A. Complete the following cleaning operations before requesting inspection for Certification of Substantial Completion.
1. Remove labels that are not permanent labels.
2. Clean exposed exterior and interior hard surfaced finishes to a dust free condition, free of stains, films and similar foreign substances.
3. The Contractor shall wipe surface of mechanical and electrical equipment. Remove excess lubrication and other substances.
4. Clean the site, including landscape development areas, of rubbish, litter and other foreign substances. Sweep paved areas broom clean; remove stains, spills and other foreign deposits. Rake grounds that are neither paved nor planted, to a smooth even-textured surface.
1.06 ADJUSTING
A. Adjust operating products and equipment to ensure smooth and unhindered operation.
END OF SECTION
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SECTION 01710
CLEANING
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Contractor shall execute cleaning, during progress of the work, and at completion of the work, as required by Contract terms.
1.02 RELATED WORK
A. Each Section: Cleaning for specific products or work.
1.03 DISPOSAL AND CLEANING
A. Conduct cleaning and disposal operations to comply with codes, ordinances, regulations and anti-pollution laws.
PART 2 PRODUCTS
2.01 MATERIALS
A. Use only those cleaning materials which will not create hazards to health or property and which will not damage surfaces.
B. Use only those cleaning materials and methods recommended by manufacturer of the surface material to be cleaned.
C. Use cleaning materials only on surfaces recommended by cleaning material manufacturer.
PART 3 EXECUTION
3.01 DURING CONSTRUCTION
A. Contractor shall execute periodic cleaning to keep the work, the site and adjacent properties free from accumulations of waste materials, rubbish and windblown debris, resulting from construction operations.
B. Contractor shall provide on-site containers for the collection of waste materials, debris and rubbish.
C. Contractor shall remove waste materials, debris and rubbish from the site periodically and dispose of at legal disposal areas away from the site.
3.02 DUST CONTROL
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A. Contractor shall clean interior spaces prior to the start of finish painting and continue cleaning on an as-needed basis until painting is finished.
B. Contractor shall schedule operations so that dust and other contaminants resulting from cleaning process will not fall on wet or newly-coated surfaces.
END OF SECTION
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SECTION 01720
PROJECT RECORD DOCUMENTS
PART 1 GENERAL
1.01 REQUIREMENTS INCLUDED
A. Maintain at the site for the Engineer one record copy of:
1. Drawings.
2. Specifications.
3. Addenda.
4. Change orders and other modifications to the contract.
5. Engineer’s field orders or written instructions.
6. Approved shop drawings, working drawings and samples.
7. Field Test Records.
8. Construction photographs and audio-video discs.
1.02 RELATED REQUIREMENTS
A. Section 01050: Field Engineering.
B. Section 01300: Shop Drawings, Product Data, Working Drawings, and Samples.
C. Section 01390: Construction Photographs
1.03 MAINTENANCE OF DOCUMENTS AND SAMPLES
A. Store documents and samples in Contractor’s field office apart from documents used for construction.
1. Provide files and racks for storage of documents.
2. Provide locked cabinet or secure storage space for storage of samples.
B. File documents and samples in accordance with CSI format.
C. Maintain documents in a clean, dry, legible, condition, and in good order. Do not use record documents for construction purposes.
D. Make documents and samples available at all times for inspection by the Owner or Engineer.
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E. As a prerequisite for monthly progress payments, the Contractor is to exhibit the currently updated “record documents” for review by the Engineer or Owner.
1.04 MARKING DEVICES
A. Provide felt tip marking pens for recording information in the color code designated by the Engineer.
1.05 RECORDING
A. Label each document “PROJECT RECORD” in neat large printed letters.
B. Record information concurrently with construction progress.
1. Do not conceal any work until required information is recorded.
C. Drawings: Legibly mark to record actual construction:
1. All underground piping with elevations and dimensions. Changes to piping location. Horizontal and vertical locations of underground utilities and appurtenances, referenced to permanent surface improvements. Actual installed pipe material, class, etc.
2. Field changes of dimension and detail.
3. Changes made by Field Order or by Change Order.
4. Details not on original contract drawings.
5. Equipment and piping relocations.
6. All underground duct banks with elevations and dimensions, horizontal and vertical locations of underground duct banks, and manholes along duct banks.
7. All underground cable elevations and horizontal locations of underground cables.
8. Depths of various elements within the construction limits.
D. Specifications and Addenda; legibly mark each section to record:
1. Manufacturer, trade name, catalog number, and supplier of each product and item of equipment actually installed.
2. Changes made by Field Order or by Change Order.
E. Shop Drawings (after final review and approval):
1. Five sets of record drawings for each process equipment, piping, electrical system and instrumentation system.
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1.06 SUBMITTAL
A. At Contract close-out, deliver Record Drawings (AutoCAD and hard copies) to the Engineer for the Owner.
B. Accompany submittal with transmittal letter in duplicate, containing:
1. Date.
2. Project title and number.
3. Contractor’s name and address.
4. Title and number of each Record Document.
5. Signature of Contractor or his authorized representative.
END OF SECTION
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SECTION 01740
WARRANTIES AND BONDS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. This Section specifies general administrative and procedural requirements for warranties and bonds required by the Subcontract Documents, including manufacturer’s standard warranties on products and special warranties.
1.02 RELATED WORK
A. Refer to Terms and Conditions of Contract for the general requirements relating to warranties and bonds.
B. General closeout requirements are included in Section 01700 Project Closeout.
C. Specific requirements for warranties for the work and products and installations that are specified to be warranted, are included in the individual Sections of Division 1 through 3.
1.03 SUBMITTALS
A. Submit written warranties to the Owner via the ENGINEER prior to the date fixed by the ENGINEER for Substantial Completion. f the Certificate of Substantial Completion designates a commencement date for warranties other than the date of Substantial Completion for the work, or a designated portion of the work, submit written warranties upon request of the Owner.
B. When a special warranty is required to be executed by the Equipment Supplier or CONTRACTOR (as applicable), or the manufacturer, prepare a written document that contains appropriate terms and identification, ready for execution by the required parties. Submit a draft to the Owner via the ENGINEER for approval prior to final execution.
C. Refer to individual Sections of Divisions 2 through 3 for specific content requirements, and particular requirements for submittal of special warranties.
D. At Final Completion compile two copies of each required warranty and bond properly executed by the CONTRACTOR, or by the Equipment Supplier (as applicable), or by the manufacturer. Organize the warranty documents into an orderly sequence based on the table of contents of the Project Manual.
E. Bind warranties and bonds in heavy-duty, commercial quality, durable 3-ring vinyl covered loose-leaf binders, thickness as necessary to accommodate contents and sized to receive 8-1/2-in by 11-in paper.
F. Table of Contents: Neatly typed, in the sequence of the Table of Contents of the Project Manual, with each item identified with the number and title of the Section in which specified and the name of the product or work item.
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G. Provide heavy paper dividers with celluloid covered tabs for each separate warranty. Mark the tab to identify the product or installation. Provide a typed description of the product or installation, including the name of the product and the name, address and telephone number of the installer, supplier and manufacturer.
H. Identify each binder on the front and the spine with the typed or printed title "WARRANTIES AND BONDS", the project title or name and the name, address and telephone number of the CONTRACTOR.
I. When operating and maintenance manuals are required for warranted construction, provide additional copies of each required warranty, as necessary, for inclusion in each required manual.
1.04 WARRANTY REQUIREMENT
A. Related Damages and Losses: When correcting warranted work that has failed, remove and replace other work that has been damaged as a result of such failure or that must be removed and replaced to provide access for correction of warranted work.
B. Reinstatement of Warranty: When work covered by a warranty has failed and been corrected by replacement or rebuilding, reinstate the warranty by written endorsement. The reinstated warranty shall be equal to the original warranty with an equitable adjustment for depreciation.
C. Replacement Cost: Upon determination that work covered by a warranty has failed, replace or rebuild the work to an acceptable condition complying with requirements of Subcontract Documents. The Equipment Supplier or CONTRACTOR (as applicable) is responsible for the cost of replacing or rebuilding defective work regardless of whether the Owner has benefited from use of the work through a portion of its anticipated useful service life.
D. Owner's Recourse: Written warranties made to the Owner are in addition to implied warranties, and shall not limit the duties, obligations, rights and remedies otherwise available under the law, nor shall warranty periods be interpreted as limitations on time in which the Owner can enforce such other duties, obligations, rights, or remedies.
E. Rejection of Warranties: The Owner reserves the right to reject warranties and to limit selections to products with warranties not in conflict with requirements of the contract Documents.
F. Disclaimers and Limitations: Manufacturer's disclaimers and limitations on product warranties do not relieve the Equipment Supplier or CONTRACTOR (as applicable) of the warranty on the work that incorporates the products, nor does it relieve manufacturers and Contractors required to countersign special warranties with the Equipment Supplier or Subcontractor (as applicable).
1.05 MANUFACTURER’S CERTIFICATIONS
A. Where required, the Equipment Supplier or CONTRACTOR (as applicable) shall supply evidence, satisfactory to the ENGINEER, that the Equipment Supplier or CONTRACTOR (as applicable) can obtain manufacturers’ certifications as to the CONTRACTOR’s installation of equipment.
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1.06 DEFINITIONS
A. Standard Product Warranties are preprinted written warranties published by individual manufacturers for particular products and are specifically endorsed by the manufacturer to the Owner.
B. Special Warranties are written warranties required by or incorporated in the Subcontract Documents, either to extend time limits provided by standard warranties or to provide greater rights for the Owner.
PART 2 PRODUCTS (NOT USED)
PART 3 EXECUTION (NOT USED)
END OF SECTION
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SECTION 02100
SITE PREPARATION
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, and equipment required and perform all site preparation, complete as shown on the Drawings and as specified herein.
B. Obtain all permits required for site preparation work prior to proceeding with the work, including clearing and tree removal.
C. The areas to be cleared, grubbed, and stripped within public rights-of-way and utility easements shall be minimized to the extent possible for the scope of pipeline work and in consideration of the actual means and methods of construction used. No unnecessary site preparation within these areas shall be performed.
1.02 RELATED WORK
A. Environmental Protection is included in Section 01110.
B. Lawn restoration is included in Section 02930.
1.03 SUBMITTALS
A. Submit in accordance with Section 01300 copies of all permits required prior to clearing, grubbing, and stripping work.
PART 2 PRODUCTS (NOT USED)
PART 3 EXECUTION
3.01 CLEARING
A. Removal of trees shall be permitted through Lee County Arborist.
B. Trees and other vegetation designated on the Drawings or directed by the Engineer to remain shall be preserved and protected as specified below.
3.02 GRUBBING
A. Grub and remove all stumps, roots in excess of 1-1/2-in in diameter, matted roots, brush, timber, logs, concrete rubble, and other debris encountered to a depth of 18-in below original grade.
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B. All grubbing holes and depressions excavated below the original ground surface shall be refilled with suitable materials and compacted to a density conforming to the surrounding ground surface in accordance with Section 02221.
3.03 DISPOSAL
A. Material and debris from site preparation operations shall be disposed of by hauling such materials and debris to an approved offsite disposal area. No rubbish or debris of any kind shall be permitted to be buried or burned on the project site.
3.04 PROTECTION
A. No construction or soil disturbance shall occur within a tree’s drip line unless protective measures to insure the protection of the tree or trees are installed.
B. Trees and other vegetation designated on the Drawings or directed by the Engineer to remain shall be protected from damage by all construction operations by erecting suitable barriers, guards, and enclosures, or by other approved means. Clearing operations shall be conducted in a manner to prevent falling trees from damaging trees and vegetation designated to remain and to the work being constructed and so as to provide for the safety of employees and others.
C. Protection shall be maintained until all work in the vicinity of the work being protected has been completed.
D. Heavy equipment operation or stockpiling of materials shall not be permitted within the branch spread of existing trees.
E. Any damage to existing tree crowns, trunks, or root systems shall be repaired immediately. Roots exposed and/or damaged during the work shall immediately be cut off cleanly inside the exposed or damaged area. Cut surfaces shall be treated with acceptable tree wound paint, and topsoil spread over the exposed root area.
F. When work is completed, all dead and downed trees shall be removed. Live trees shall be trimmed of all dead and diseased limbs and branches. All cuts shall be cleanly made at their juncture with the trunk or preceding branch without injury to the trunk or remaining branches. Cuts over 1-inch in diameter shall be treated with acceptable tree wound paint.
G. Construction activities shall be restricted to those areas within the limits of construction designated on the Drawings, within public rights-of-way, and within easements provided by the Owner. Adjacent properties and improvements thereon, public or private, which become damaged by construction operations, shall be promptly restored to their original condition, to the full satisfaction of the property owner.
END OF SECTION
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SECTION 02140
DEWATERING AND DRAINAGE
PART 1 GENERAL
1.01 STATUTORY REQUIREMENTS
A. Obtain and pay for all permits required for temporary dewatering and drainage systems.
B. Original permits shall be prominently displayed on the Work site prior to constructing dewatering and drainage systems.
1.02 SCOPE OF WORK
A. Furnish, install, operate, monitor, maintain, and remove temporary dewatering and drainage systems as necessary to lower and maintain groundwater levels below subgrades of excavations and prevent surface water runoff from entering or accumulating in excavations, to permit construction in the dry.
B. Collect and properly dispose of all discharge water from dewatering and drainage systems in accordance with State and local requirements and permits.
C. Repair any damage caused by dewatering and drainage system operations.
D. Remove temporary dewatering and drainage systems when no longer needed, and restore all disturbed areas.
1.03 RELATED WORK
A. Trenching, backfilling and compaction are included in Section 02221.
B. Sedimentation and erosion control is included in Section 01110.
1.04 SUBMITTALS
A. Submit in accordance with Section 01300 the temporary dewatering and drainage system designs. Dewatering and drainage system designs shall be prepared by a licensed professional Engineer, registered in Florida, having a minimum of five (5) years of professional experience in the design and construction of dewatering and drainage systems. Submittal will be for information only. Contractor shall remain responsible for adequacy and safety of construction means, methods and techniques.
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1.05 DEFINITIONS
A. Where the phrase "in-the-dry" is used in these specifications, it shall be defined as soil conditions that are no more than two percentage points above the optimum moisture content for that soil.
PART 2 PRODUCTS (NOT USED)
PART 3 EXECUTION
3.01 GENERAL
A. Surface water and groundwater shall be controlled such that excavation to final grade is made in-the-dry, the bearing soils are maintained undisturbed. Prevent softening or instability of, or disturbance to, the subgrade due to the presence or seepage of water.
B. All work shall be protected from flotation.
C. The impact of anticipated subsurface soil/water conditions shall be factored into the selection of methods of excavation and proposed dewatering and drainage systems. Where groundwater levels are above the proposed bottoms of excavations, it is expected that some type of pumped dewatering system will be required for predrainage of the soils prior to excavation to final grade and for maintaining the lowered groundwater level until construction has been completed to such an extent that the foundation, structure, pipe, conduit, or fill will not be floated or otherwise damaged. It is further expected that the type of system, spacing of dewatering units, and other details of the work will vary depending on soil/water conditions at a particular location.
3.02 SURFACE WATER CONTROL
A. Surface water control measures shall be constructed to prevent flow of surface waters into excavations. Such measures may include dikes, ditches, and sumps.
3.03 EXCAVATION DEWATERING
A. Provide and maintain adequate equipment and facilities to remove promptly and dispose of properly all water entering excavations. Excavations shall be kept in-the-dry, so as to maintain an undisturbed subgrade condition throughout construction below grade, including backfill and fill placement.
B. Water entering excavations from precipitation or surface runoff shall be collected in shallow ditches around the perimeter of the excavation, drained to sump, and pumped from the excavation to maintain in-the-dry conditions.
C. Pipe and conduit shall not be laid in water or allowed to be submerged prior to backfilling. Pipe and conduit which becomes submerged shall be removed and the excavation dewatered and restored to proper conditions prior to reinstalling the pipe and conduit.
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D. Excavations for foundations and structures shall be maintained in-the-dry for a minimum of four days after concrete placement. In no event shall water be allowed to enter an excavation and rise to cause unbalanced pressure on foundations and structures until the concrete or mortar has set at least 24 hours.
E. Dewatering and drainage operations shall at all times be conducted in such a manner as to preserve the natural undisturbed bearing capacity of the subgrade at the bottom of the excavation. If the subgrade becomes disturbed for any reason, the unsuitable subgrade material shall be removed and replaced with concrete, compacted granular fill, or other approved material to restore the bearing capacity of the subgrade to its natural undisturbed condition.
F. Dewatering and drainage operations shall be conducted in a manner which does not cause loss of ground or disturbance to the pipe bedding or soil which supports overlying or adjacent structures.
3.04 DISPOSAL OF DRAINAGE
A. All water discharged from temporary dewatering and drainage systems shall be disposed of in accordance with the appropriate regulatory agencies. This includes all necessary containment and disposal associated with drilling or jack and boring.
END OF SECTION
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SECTION 02151
JACKING
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment, supplies and incidentals required to install casing pipe and carrier pipe by jacking under the roadways at the locations shown on the Drawings.
B. Work shall be done in strict accordance with the details shown on the Drawings and as specified herein and in accordance with all state and local laws, regulations and requirements. Work shall also comply with the requirements of the Florida Department of Transportation.
C. The work shall include, but not be limited to, the following: steel casing pipe, skids, casing seals, coatings, location markers and miscellaneous appurtenances as required to complete the installation.
D. Furnish special insurance, traffic control, flaggers and any other requirements imposed by the owner of the right(s)-of-way over the work.
E. Be fully responsible for inspecting the location where the pipes are to be installed and shall familiarize himself with the conditions under which the work will be performed and with all necessary details as to the orderly performance of the work. The omission of any details for the satisfactory installation of the work in its entirety which may not appear herein shall not relieve the Contractor of full responsibility.
F. Prepare to work at night and on Saturday and Sunday, if required to complete the work. After the operation has begun, work continuously (24 hours a day) until the complete length of pipe has been installed.
G. If any movement or settlement occurs which causes or might cause damage to existing structure over, along or adjacent to the work, immediately stop any or all work except that which assists in making the work secure and in preventing further movement, settlement or damage. Resume jacking only after all necessary precautions have been taken to prevent further movement, settlement or damage, and repair the damage, at the Contractor's own cost and to the satisfaction of the Engineer.
H. An FDOT Utility Permit, Permit No. #####, has been obtained for work to be preformed within FDOT rights-of-way and crossing FDOT roadways. All work related to the FDOT permit shall conform to all permit requirements.
I. A permit for jacking under Lee County roadways may be required from Lee County DOT. It shall be the sole responsibility of the Contractor to submit the necessary permit and data to the appropriate authority and receive approval thereof.
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1.02 RELATED WORK
A. Site Preparation is included in Section 02100.
B. Dewatering and Drainage is included in Section 02140.
C. Trenching, Excavation and Backfill is included in Section 02221.
D. Environmental Protection Procedures is included in Section 01110.
E. Ductile Iron Pipe and Fittings are included in Section 02616.
F. Valves, Hydrants and Appurtenances are included in Section 02640.
G. Seeding is included in Section 02930.
H. Concrete work is included in Division 3.
1.03 SUBMITTALS
A. Submit in accordance with Section 01300 complete shop drawings and product data for casing pipe, carrier pipe, fittings and related appurtenances. Submit a lay schedule showing stationing, elevations, pipe classes and class coding.
B. At least 30 days prior to the scheduled start of any jacking operations, submit in accordance with Section 01300 the proposed methods of jacking. Review will be for information only. Remain responsible for adequacy and safety of construction means, methods and techniques. Submittals shall consist of design drawings, calculations and related supplemental information describing in detail the design concept for all jacking operations. Submittals shall include as a minimum the following:
1. Shop drawings showing size, location and design calculations for reaction blocks and jacking pits.
2. Number and capacities of jacks.
3. Size, arrangement and installation of soil stabilization and dewatering equipment with details of locations where groundwater will be directed during construction.
4. Detailed descriptions of equipment, materials, sequence and procedures for jacking steel sleeve with shield including provisions for standby and backup equipment.
5. Revisions to shop drawings, as necessary, to accommodate field conditions and/or compliance as specified herein.
C. Should the owner of a right-of-way over the work require approval of jacking designs and shop drawings, furnish submittals to that owner and obtain the necessary approvals prior to furnishing the submittals specified above.
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1.04 REFERENCE STANDARDS
A. American Society for Testing and Materials (ASTM)
1. ASTM A36 - Standard Specification for Structural Steel.
2. ASTM A53 - Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc Coated Welded and Seamless.
3. ASTM A134 - Standard Specification for Electric-Fusion (ARC) Welded Steel Plate Pipe (Sizes 16 inches and over).
4. ASTM A139 - Standard Specification for Electric-Fusion (ARC) Welded Steel Pipe (Sizes 4-in and over).
B. American Water Works Association (AWWA):
1. AWWA C111 – Rubber - Gasket joints for ductile-iron pressure pipe fittings.
2. AWWA C200 - Standard for Steel Water Pipe 6-in and larger.
3. AWWA C203 - Standard for Coal-Tar Protective Coatings and Linings for Steel Water Pipelines - Enamel and Tape - Hot-Applied.
4. AWWA C206 - Standard for Field Welding of Steel Water Pipe.
C. American Welding Society (AWS)
D. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.
1.05 QUALITY ASSURANCE
A. Steel casing pipe shall be the product of a single domestic manufacturer. Pipe shall be tested and inspected at the foundry as required by the standard specifications to which the material is manufactured. Submit in accordance with Section 01300 sworn certificates of such tests, results and satisfactory approvals.
B. All pipe to be installed under this Contract may be inspected at the site of manufacture for compliance with these Specifications by an independent laboratory selected by the Owner. The manufacturer's cooperation shall be required in these inspections. The cost of any inspection requested by the Owner of all pipe approved for this Contract shall be borne by the Owner. The cost of inspection of any disapproved pipe shall be borne by the Contractor.
C. Welders shall be certified in accordance with standards of the American Welding Society. Submit current certifications prior to the start of field work.
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1.06 SYSTEM DESCRIPTION
A. The completed installation shall be suitable in all respects for transporting domestic sewage without affecting the stability and integrity of the overlying roadways and roadbeds.
1.07 DELIVERY, STORAGE AND HANDLING
A. Care shall be taken in loading, transporting and unloading to prevent injury to the pipe or coatings. Pipe shall not be dropped. Any damage to the pipe coatings shall be repaired in accordance with the pipe manufacturer’s procedures.
B. All pipe shall be subjected to a careful inspection prior to being installed. If any pipe fails to meet the Specifications, it shall be removed and replaced with satisfactory pipe.
1.08 PROJECT/SITE REQUIREMENTS
A. Discharge from dewatering operations shall be directed into approved receiving basins in accordance with all applicable regulatory requirements.
B. Furnish all maintenance of traffic and establish and maintain all safety procedures on adjacent highways during the jacking operation.
C. Inspect the locations where jacking operations will be conducted and the casing pipe is to be installed, verify the conditions under which the work will be performed, and provide all necessary details, whether shown or specified on the Drawings or not, for the orderly prosecution of the work.
D. Be prepared to work at night and on weekends, if required, to complete the work. Request and obtain written authorization in accordance with the General Conditions prior to working nights and weekends.
E. Jacking operations shall not result in measurable settlement, movement, or cracking of roadways or roadbeds or adjacent structures. If any movement or settlement occurs which causes or might cause damage to roadways or roadbeds or structures over, along, or adjacent to the work, jacking operations shall stop immediately except for those activities which will assist in making the work secure and prevent further movement, settlement, or damage. Jacking operations may resume only after all necessary precautions have been taken to prevent further movement, settlement, or damage.
F. Roadways or roadbeds and structures damaged by jacking operations shall be repaired or replaced as necessary to restore them to their condition prior to beginning jacking operations.
1.09 DEFINITIONS
A. Casing pipe shall mean the outer sleeve which is installed by the bore and jack method.
B. Carrier pipe shall mean the pipe inserted within the casing pipe and which acts as the conveyor of liquid or gas.
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C. Jacking pit shall mean the pit in which the boring and jacking equipment is installed and from which both the casing pipe and carrier pipe are launched.
D. Exit pit shall mean the pit located at the end of the casing pipe remote from the jacking pit at the point where the carrier pipe emerges from the casing pipe.
PART 2 PRODUCTS
2.01 GENERAL
A. The use of a manufacturer's name and model or catalog number is for the purpose of establishing the standard of quality and general configuration desired.
2.02 MATERIALS
A. Steel Casing Pipe
1. Steel casings shall be of leakproof construction and shall conform to the requirements of ASTM A139 Grade "B" and shall be protected inside and outside by a black bituminous coating a minimum of 5 mils thick. Steel casing pipe shall have a minimum yield strength of 35,000 psi, shall be equipped with grout holes as specified herein, and shall be designed to withstand H-20 traffic and Coopers E-80 Railroad loadings for roadways and railroads, respectively.
2. Casing pipes shall have the minimum nominal diameters and wall thicknesses as shown on the Drawings. In the event that the steel casing pipe wall thicknesses are not shown on the Drawings, the following wall thicknesses shall be used:
Carrier Pipe Casing Pipe Casing Nominal Diameter Nominal Diameter Wall Thickness 8” 18” 0.250 10” 20” 0.250 12” 24” 0.312 16” 30” 0.312 18” 30” 0.312 20” 36” 0.375 24” 42” 0.500
B. Carrier Pipe
1. All carrier pipe joints within the casing pipe shall be restrained or harnessed.
2. PVC pipe and fittings shall be as shown on the Drawings and as specified in Section 02622.
C. Stainless steel carriers with teflon skids, of The Booster Casing Spacers, being on center and restrained shall be the preferred method for installing the carrier pipe. Skids shall be installed 7 feet or less, on center. After the carrier pipe has been tested for leakage, the casing shall have the ends
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blocked with either an 8" wall of brick masonry with a weep hole at the bottom, or Cascade Model CCES End Seals with stainless steel bands.
2.03 MIXES
A. Mortar shall consist of one part cement, 1/4 part lime and two parts sand. Sand shall comply with ASTM C144. Lime shall comply with ASTM C207, Type S. Cement shall comply with ASTM C150, Type II.
B. Cement grout shall consist of a mixture of about 1 part cement to 6 parts sand. The amount of cement may be increased or decreased as necessary and as permitted to provide good flowing characteristics.
2.04 SURFACE PREPARATION AND SHOP COATINGS
A. Steel casing pipe shall be protected inside and outside by a black bituminous coating with a minimum thickness of 5 mils.
PART 3 EXECUTION
3.01 JACKING PITS
A. The pits shall be shaped with steel sheet piling or other materials that shall be of adequate strength. Braced steel sheeting shall be used to support the sides of the excavation for the pits.
B. Furnish, install and remove, to the extent required, thrust blocks or whatever provisions may be required in driving the sleeves and pipes forward.
C. Steel rails or beams embedded in the concrete shall be used in the pit for placement and alignment of each piece of steel sleeve or ductile iron pipe during installation operations.
D. Be fully responsible for the removal of the pits including the breaking up, removing and disposing of concrete, if so required, or cutting off of sheeting and furnishing and placing screened gravel fill to the normal subgrade as may be required following the installation operations.
3.02 JACKING OPERATIONS
A. Be fully responsible for preventing the occurrence of voids outside the jacking sleeve and if they occur, fill them with cement grout. In order to minimize the amounts of voids produced during excavation in the forward end of the sleeve, a jacking shield shall be required.
B. Immediately following the jacking operation, pressure grout the jacked section to fill all voids existing outside of the jacked sleeve. Grouting shall be from the interior of the sleeve through grouting holes.
C. Proper alignment and elevation of the sleeves or pipes shall be consistently maintained throughout the jacking operation.
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D. Be required to use a jacking ring consisting of either steel or concrete construction. This jacking ring will allow the jacking pressure to be distributed evenly around the wall of the jacking pipe.
E. The use of a jacking frame shall be required. It shall be fabricated from structural steel members and shall be designed to distribute the stresses from the jacks evenly to the jacking ring.
F. Steel sleeve sections shall have beveled ends with a single v-groove and shall be full penetration butt welded on the outside of the sleeve in accordance with the applicable portions of AWWA C206 and AWS D7.0 for the field welded water pipe joints. All joints of the steel sleeve shall be butt welded prior to being subject to the jacking operation. The welded joints shall be wire brushed and painted with bitumastic enamel coating in accordance with AWWA C203.
G. After the sleeve has been completely installed, thoroughly clean the interior. Place within the sleeve, the pipe using plastic (steel) casing insulator skids as shown on the Drawings.
H. Upon completion of installation of the carrier pipe inside the casing pipe, provide suitable restrained caps or plugs at each joint outside the end of the casing pipe and hydrostatically test the carrier pipe as designated by the Engineer. Any leaks which are discovered during the testing phase shall be repaired to the satisfaction of the Engineer.
I. If brick bulkheads are utilized they shall be 8-in wide minimum and shall be installed at each end of the sleeve after the pipe has been installed. The portion of the pipe passing through the brick bulkhead shall be wrapped with three layers of 15 lb asphalt impregnated felt before the bulkhead is constructed.
J. If a pipe is laid within a 1.5 to 1 slope from a point 10-ft off of the tracks centerline, take precaution to keep the soil from running by either sheeting or other approvable methods to the Engineer of Design of the Railroad.
3.03 GROUTING AND FILLING
A. Sleeves and pipes for jacking shall have grout holes equipped with pipe half-couplings. The 2-in standard pipe half-couplings welded into the holes in the sleeve or pipe walls shall be filled with threaded cast iron plugs. Three grout holes spaced at 120 degrees on center shall be installed at 4 linear feet intervals.
B. Systems of standard pipe, fittings, hose and special grouting outlets embedded in the sleeve or pipe walls shall be furnished. Care shall be taken to insure that all parts of the system are maintained free from dirt. Cement grout shall be forced under pressure into the grouting connections. Grouting shall be started in the lowest connections and shall proceed until grout begins to flow from upper connections. Connections shall then be made to these holes and the operation continued to completion.
C. Apparatus for mixing and placing grout shall be capable of mixing effectively and stirring the grout and then forcing it into the grout connections in a continuous uninterrupted flow.
D. After grouting is complete, pressure shall be maintained by means of stop cocks or other suitable devices until the grout has set sufficiently. After the grout is set, grout holes shall be completely filled with dense concrete and finished neatly without evidence of voids or projections.
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E. The pipe shall be installed to the exact line and grade required within the casing.
F. Pipe to be installed within casings must be supported with spacers as specified.
3.04 SITE RESTORATION
A. At the conclusion of all jacking operations, remove excavation support systems for jacking pits. If withdrawal should damage or disturb the roadway or roadbed subgrade, leave supports in place and cut off 36-in below finished grade.
B. Following pipe installation and backfill operations, restore the profile of the right-of-way to its original condition. Construct sidewalks and fencing, if applicable, to match existing. Install sodding or seeding to match existing, as required.
C Remove all equipment, supplies, excess excavation materials and miscellaneous items associated with the jacking operation and leave the site in a clean and tidy condition.
D. If required by the Owner of the right-of-way, coordinate and schedule a final inspection of the work by the Owner of the right-of-way.
END OF SECTION
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SECTION 02221
TRENCHING, BACKFILLING AND COMPACTION
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals necessary to perform all trenching for pipelines and appurtenances, including drainage, filling, backfilling, disposal of surplus material and restoration of trench surfaces and easements.
B. Excavation shall extend to the width and depth shown on the Drawings or as specified and shall provide suitable room for installing pipe, structures and appurtenances.
C. The Contractor shall furnish and place all sheeting, bracing and supports and shall remove from the excavation all materials which the Engineer may deem unsuitable for backfilling. The bottom of the excavation shall be firm, dry and in all respects, acceptable. If conditions warrant, the Contractor may be ordered to deposit gravel for pipe bedding, or gravel refill for excavation below grade, directly on the bottom of the trench immediately after excavation has reached the proper depth and before the bottom of the trench has become softened or disturbed by any cause whatever. The length of open trench shall be related closely to the rate of pipe laying. All excavation shall be made in open trenches.
D. All excavation, trenching and related sheeting, bracing, etc, shall comply with the requirements of OSHA excavation safety standards (29 CFR Part 1926.650 Subpart P) and Florida Trench Safety Act (F.S. 553). Where conflict between OSHA and State regulations exists, the more stringent requirements shall apply.
E. Wherever the requirement for 98 percent compaction is referred to herein it shall mean "at least 98 percent of maximum dry density as determined by ASTM D698”.
F. Prior to the start of work the Contractor is required to submit his/her proposed method of backfilling and compaction to the Engineer for review.
1.02 SOIL TESTING FOR COMPACTION
A. One compaction test location shall be required for each 500 linear feet of pipe per 1-foot lift of fill and for every 100 square feet of backfill around structures as a minimum. The Engineer may determine that more compaction tests are required to certify the installation depending on field conditions. The locations of compaction test within the trench shall be in conformance with the following schedule:
1. One test at the spring line of the pipe.
2. At least one test for each bedding zone for pipes 24 inches and larger.
3. One test at an elevation of one foot above the top of the pipe.
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4. One test for each one foot of backfill placed from one foot above the top of the pipe to finished grade elevation.
B. Payment for testing will be made by the contractor from the allowance in the Bid Form. If test results are unsatisfactory, all costs involved in correcting deficiencies in compacted materials to the satisfaction of the Engineer, will be borne by the Contractor.
C. Compaction percent density will be determined by ASTM D698.
1.03 CHEMICAL SOIL TESTING
A. The Contractor shall submit representative samples of proposed common fill and sand fill, each sample weighing approximately 50-lbs, at least ten days prior to the date of anticipated use of such material.
B. The fill material will be analyzed for metals, volatile organic compounds (VOC), cyanide, and total petroleum hydrocarbons.
C. Payment for testing will be made by the Owner out of an allowance provided in the bid form.
D. Fill material shall not be used for backfilling until approved by the Engineer.
1.04 RELATED WORK
A. Granular fill material is included in Section 02230.
B. Dewatering is included in Section 02140.
C. Seeding is included in Section 02930.
D. Pavement repair and resurfacing is included in Section 02576.
PART 2 PRODUCTS
2.01 FILL MATERIALS
A. Common Fill is specified in Section 02230.
B. Sand
1. Sand shall conform to ASTM C33 for fine aggregate.
2.02 FLOWABLE FILL
A. The materials shall conform with the requirements specified in FDOT Standard Specifications for Road and Bridge Construction (2010 edition) Section Number 121. Specific references are as follows:
1. Portland Cement (Types I, II, or III) Section 921
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2. Fly Ash, Slag and other Pozzolanic Materials for Portland Cement Concrete Section 929
3. Fine Aggregate (Sand) * Section 902
4. Water Section 923
* Any clean sand with 100% passing a 3/8" sieve and not more than 15% passing the 200 mesh sieve may be used.
PART 3 EXECUTION
3.01 TRENCH EXCAVATION
A. Trench excavation shall include material of every description and of whatever substance encountered, except rock and boulders. Pavement shall be cut with a saw, wheel or pneumatic chisel along straight lines before excavating.
B. The Contractor shall strip and stockpile topsoil from grassed areas crossed by trenches. At the Contractor's option, topsoil may be otherwise disposed of and replaced, when required, with approved topsoil of equal quality.
C. While excavating and backfilling is in progress, traffic shall be maintained, and all utilities and other property protected as provided in the General Conditions and General Requirements.
D. Trenches shall be excavated to the depth indicated on the Drawings and in widths sufficient for laying the pipe, bracing and for pumping and drainage facilities. The bottom of the excavations shall be firm and dry and in all respects acceptable to the Engineer. Trench width shall be practical minimum.
E. Excavation and dewatering shall be accomplished by methods which preserve the undisturbed state of subgrade soils. The trench may be excavated by machinery to, or just below the designated subgrade, provided that material remaining in the bottom of the trench is no more than slightly disturbed. Subgrade soils which become soft, loose, "quick", or otherwise unsatisfactory as a result of inadequate excavation, dewatering or other construction methods shall be removed and replaced by screened gravel fill as required by the Engineer at the Contractor's expense.
F. Clay and organic silt soils are particularly susceptible to disturbance due to construction operations. When excavation is to end in such soils, the Contractor shall use a smooth-edge bucket to excavate the last one foot of depth.
G. Where pipe is to be laid in screened gravel bedding, the trench may be excavated by machinery to the normal depth of the pipe provided that the material remaining in the bottom of the trench is no more than slightly disturbed.
H. Where pipe is to be laid directly on the trench bottom, final excavation at the bottom of the trench shall be performed manually, providing a flat-bottom true to grade upon undisturbed material. Bell holes shall be made as required.
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3.02 DISPOSAL OF MATERIALS
A. Excavated material shall be stacked without excessive surcharge on the trench bank or obstructing free access to hydrants and gate valves. Inconvenience to traffic and abutters shall be avoided as much as possible. Excavated material shall be segregated for use in backfilling as specified below.
B. It is expressly understood that no excavated material shall be removed from the site of the work or disposed of by the Contractor except as directed by the Engineer. When removal of surplus materials has been approved by the Engineer, the Contractor shall dispose of such surplus material in approved areas designated by the Contractor.
C. Should conditions make it impracticable or unsafe to stack material adjacent to the trench, the material shall be hauled and stored at a location provided by the Contractor. When required, it shall be re-handled and used in backfilling the trench.
3.03 SHEETING AND BRACING
A. Furnish, put in place and maintain sheeting and bracing required by Federal, State or local safety requirements to support the sides of the excavation and prevent loss of ground which could endanger personnel, damage or delay the work or endanger adjacent structures. If the Engineer is of the opinion that at any point sufficient or proper supports have not been provided, he/she may order additional supports placed at the expense of the Contractor. Compliance with such order shall not relieve the Contractor from his/her responsibility for the sufficiency of such supports. Care shall be taken to prevent voids outside of the sheeting, but if voids are formed, they shall be immediately filled and rammed.
B. Provide trench box clarification.
C. When moveable trench bracing such as trench boxes, moveable sheeting, shoring or plates are used to support the sides of the trench, care shall be taken in placing and moving the boxes or supporting bracing to prevent movement of the pipe, or disturbance of the pipe bedding and the screened gravel backfill.
1. When installing flexible pipe (PVC, etc.) trench boxes, moveable sheeting, shoring or plates shall not be allowed to extend below mid-diameter of the pipe. As trench boxes, moveable sheeting, shoring or plates are moved, screened gravel shall be placed to fill any voids created and the screened gravel and backfill shall be recompacted to provide uniform side support for the pipe.
2. When installing rigid pipe (D.I., R.C., etc.), any portion of the box extending below mid diameter shall be raised above this point prior to moving the box ahead to install the next pipe. This is to prevent the separation of installed pipe joints due to movement of the box.
D. The Contractor will be permitted to use steel sheeting in lieu of wood sheeting for the entire job wherever the use of sheeting is necessary. The cost for use of sheeting will be included in the bid items for pipe and shall include full compensation for driving, bracing and later removal of sheeting.
E. All sheeting and bracing shall be carefully removed in such manner as not to endanger the construction of other structures, utilities, or property, whether public or private. All voids left after
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withdrawal of sheeting shall be immediately refilled with sand by ramming with tools especially adapted to that purpose, by watering or otherwise as directed.
F. The Contractor shall receive no payment, for sheeting, bracing, etc., during the progress of the work. The Contractor shall receive no payment for sheeting which has actually been left in the trench for the convenience of the Contractor.
G. Sheeting driven below mid-diameter of any pipe shall remain in place from the driven elevation to at least 1 foot above the top of the pipe.
3.04 TEST PITS
A. The Contractor may be required to excavate test pits for the purpose of locating underground utilities or structures as an aid in establishing the precise location of new work.
B. Test pits shall be backfilled as soon as the desired information has been obtained. The backfilled surface shall be maintained in a satisfactory condition for travel until resurfaced as specified.
3.05 EXCAVATION BELOW GRADE AND REFILL
A. Whatever the nature of unstable material encountered or the groundwater conditions, trench drainage shall be complete and effective.
B. If the Contractor excavates below grade through error or for his/her own convenience, or through failure to properly dewater the trench, or disturbs the subgrade before dewatering is sufficiently complete, he/she may be directed by the Engineer to excavate below grade as set forth in the following paragraph, in which case the work of excavating below grade and furnishing and placing the refill shall be performed at his/her own expense.
C. If the material at the level of trench bottom consists of fine sand, sand and silt or soft earth which may work into the screened gravel notwithstanding effective drainage, the subgrade material shall be removed to the extent directed and the excavation refilled with a 6-in layer of coarse sand, or a mixture graded from coarse sand to the fine peastone, as approved by the Engineer, to form a filter layer preserving the voids in the gravel bed of the pipe. The composition and gradation of gravel shall be approved by the Engineer prior to placement. Screened gravel shall then be placed in 6-in. layers thoroughly compacted up to the normal grade of the pipe. If directed by the Engineer, bank-run gravel shall be used for refill of excavation below grade.
D. Geotextile filter fabric may be substituted for filter layer if approved by the Engineer. Filter fabric shall be Mirafi 140N, Supac equivalent, or equal.
3.06 BACKFILLING
A. As soon as practicable after the pipe has been laid and jointed, backfilling shall begin and thereafter be prosecuted expeditiously. Bedding gravel, as specified for the type of pipe installed, shall be placed up to 1 foot over the pipe.
B. Where the pipes are laid cross country, the remainder of the trench shall be filled with common fill material in layers not to exceed 1 foot and mounded 6-in above the existing grade or as directed. Where a loam or gravel surface exists prior to cross country excavations, it shall be
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removed, conserved and replaced to the full original depth as part of the work under the pipe items. In some areas it may be necessary to remove excess material during the clean-up process, so that the ground may be restored to its original level and condition.
C. As an alternative, or under State Roadways, Flowable Fill may be substituted. When using Flowable Fill a fabric mesh shall be installed between the "first lift" and the Flowable Fill.
D. To prevent longitudinal movement of the pipe, dumping backfill material into the trench and then spreading will not be permitted until selected material or screened gravel has been placed and compacted to a level 1 foot over the pipe.
E. Backfill shall be brought up evenly on all sides. Each layer of backfill material shall be thoroughly compacted by rolling, tamping, or vibrating with mechanical compacting equipment or hand tamping, to 98 percent Standard Proctor compaction. If rolling is employed, it shall be by use of a suitable roller or tractor, being careful to compact the fill throughout the full width of the trench.
F. Where other methods are not practicable, compaction shall be by use of hand or pneumatic ramming with tools weighing at least 20 lbs. The material being spread and compacted in layers shall be not over 6-in thick. If necessary, sprinkling shall be employed in conjunction with rolling or ramming.
G. Backfill around structures shall be selected common fill material, may be compacted by puddling where approved by the Engineer. All backfill shall be compacted, especially under and over pipes connected to the structures.
H. Subject to the approval of the Engineer, fragments of ledge and boulders smaller than 3-in may be used in trench backfill providing that the quantity in the opinion of the Engineer, is not excessive. Rock fragments shall not be placed until the pipe has at least 2-ft of earth cover. Small stones and rocks shall be placed in thin layers alternating with earth to insure that all voids are completely filled. Fill shall not be dropped into the trench in a manner to endanger the pipe.
I. Bituminous paving shall not be placed in backfilling unless specifically permitted, in which case it shall be broken up as directed. Frozen material shall not be used under any circumstances.
J. All road surfaces shall be broomed and hose-cleaned immediately after backfilling. Dust control measures shall be employed at all times.
3.07 RESTORING TRENCH SURFACE
A. Where the trench occurs adjacent to paved streets, in shoulders, sidewalks, or in cross-country areas, the Contractor shall thoroughly consolidate the backfill and shall maintain the surface as the work progresses. If settlement takes place, he/she shall immediately deposit additional fill to restore the level of the ground.
B. In and adjacent to streets, the top 12-in layer of trench backfill shall consist of compacted FDOT approved material. Should the Contractor wish to use material excavated from the trench as gravel sub-base for pavement replacement, the Contractor shall at his/her own expense have samples of the material tested by an independent testing laboratory at intervals not to exceed 500 feet, in
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order to establish its compliance with the specifications. Only material which has been tested by the Contractor and approved by the Engineer shall be allowed to be incorporated into the work.
C. The surface of any driveway or any other area which is disturbed by the trench excavation and which is not a part of the paved road shall be restored by the Contractor to a condition at least equal to that existing before work began.
D. In sections where the pipeline passes through grassed areas, the Contractor shall, at his/her own expense, remove and replace the sod, or shall loam and seed the surface to the satisfaction of the Engineer.
END OF SECTION
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SECTION 02222
ROADWAY CORSSINGS BY OPEN CUT
PART 1 GENERAL
1.1 SCOPE OF WORK
The CONTRACTOR shall provide all labor, materials, equipment, supervision and incidentals required to install the pipeline as shown on the Drawings in Lee County Streets by method of open cut.
1.2 SUBMITTAL
A. Submit shop drawings to the ENGINEER for review.
B. Before starting work, the CONTRACTOR shall submit to the Lee County Department of Transportation, with copy to the ENGINEER, a detailed schedule of his operations a minimum of fourteen (14) days prior to beginning work for approval. This shall include, but not be limited to, type and extent of temporary paving, and drawings and lists describing materials and traffic control methods to be used. Approval shall not relieve the CONTRACTOR of his obligation to provide a safe and proper crossing.
C. The CONTRACTOR shall engage the services of a Professional Engineer who is registered in the State of Florida to design all cofferdam and sheeting and bracing systems which the CONTRACTOR feels necessary for the execution of his work. The CONTRACTOR's Engineer shall submit to the ENGINEER a signed statement that he has been employed by the CONTRACTOR to design all sheeting and bracing systems. After the systems have been installed, the CONTRACTOR's Engineer shall furnish to the ENGINEER an additional signed statement that the cofferdams and sheeting and bracing systems have been installed in accordance with his design.
D. If a detour is required, a traffic control plan shall be submitted for approval to Lee County and/or the Florida Department of Transportation.
E. A plan for maintenance of traffic in accordance with Index 600 through 650 of the Florida Department of Transportation Specifications shall be submitted by the CONTRACTOR.
PART 2 PRODUCTS
2.1 MATERIALS
Materials shall meet those specified in other applicable portions of this Specification.
PART 3 EXECUTION
3.1 GENERAL
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A. Trench dimensions for open cutting of road crossings are shown on the Drawings.
B. The CONTRACTOR will be limited to a 24-hour period to complete the open-cut crossing. The road surface shall be repaved, with temporary pavement, if necessary, at the end of the 24-hour period.
C. The CONTRACTOR shall notify Lee County DOT forty-eight (48) hours in advance of starting construction.
3.2 INSTALLATION
A. Temporary Roadways
1. Temporary roadways required for traffic relocation shall be constructed of materials meeting the requirements of the FOOT. Temporary roadways shall be used when crossing a state highway right-of-way or at the direction of the ENGINEER.
2. Temporary roadways shall be maintained in good condition throughout their use.
3. Drainage shall be maintained through all existing ditches by the use of culvert pipe as necessary.
4. Drawings indicating the type and location of temporary roadways shall be submitted as discussed in Paragraph 1.04.C. for approval prior to beginning work.
5. Where detours are permitted, the CONTRACTOR shall provide all necessary barricades and signs as required to divert the flow of traffic. While traffic is detoured, the CONTRACTOR shall expedite construction operations and periods when traffic is being detoured will be strictly controlled by the ENGINEER.
6. Lee County DOT will inspect all work being done.
7. All work at the roadway crossing shall be performed and completed in a manner fully satisfactory to Lee County DOT.
B. Maintenance of Traffic
1. The requirements specified herein are in addition to the plan for Maintenance of Traffic as specified in Sections 01041 and 01570.
2. The CONTRACTOR shall furnish during construction and any subsequent maintenance within State secondary road right-of-ways and Lee County streets, proper signs, signal lights, flagmen, and other warning devices for the protection of traffic all in conformance with the latest Manual on Uniform Traffic Control and Safe Streets and Highways, and the Florida Manual of Traffic Control and Safe Practices for Street and Highway Construction, Maintenance and Utility Operations. Information as to the above may be obtained from FOOT Division engineers. The ENGINEER, County Engineer, or FOOT Manager of the right-of- way of their representatives reserves the right to stop any work for noncompliance.
3. The CONTRACTOR shall take precautions to prevent injury to the public due to open trenches. Night watchmen may be required where special hazards exist, or police protection 5000-79695 02222-2 Florida Governmental Utility Authority Waterway Estates Interconnect 60% Submittal
provided for traffic while work is in progress. The CONTRACTOR shall be fully responsible for damage or injuries whether or not police protection has been provided.
4. Unless permission to close a County street is received in writing from the proper authority, all excavated material shall be placed so that vehicular and pedestrian traffic may be maintained at all times. If the CONTRACTOR's operations cause traffic hazards, he shall repair the road surface, provide temporary ways, erect wheel guards or fences, or take other measures for safety satisfactory to the ENGINEER.
5. The CONTRACTOR shall be fully responsible for the installation of adequate safety precautions, for maintenance of the channelization devices, and for the protection of the traveling public.
6. At all open cut crossings, a minimum of one-way traffic shall be maintained during the daylight hours, and two-way traffic at night.
C. Installation of Pipeline
1. Pavement removal, sheeting, shoring and bracing, excavation and backfill, and dewatering shall meet the requirements of the applicable portions of this Specification.
2. The pipe shall be installed in accordance with Division 2 of these Specifications.
3. The trench shall be backfilled in accordance with the requirements of Section 02221.
4. Pavement replacement shall be in accordance with Section 02575 of this Specification.
5. Open cut crossings of roadway and driveways shall be sequenced in such a way as to maintain access and egress for businesses, schools, private residences, normal and emergency services.
END OF SECTION
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SECTION 02230
GRANULAR MATERIALS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals necessary to obtain materials for filling and backfilling, grading and miscellaneous site work, for the uses shown on the Drawings and as specified herein.
1.02 RELATED WORK
A. Testing and Testing Laboratory Services is included in Section 01410.
B. Site Preparation is included in Section 02100.
C. Dewatering and Drainage is included in Section 02140.
D. Trenching, Backfilling and Compaction are included in Section 02221.
E. Sedimentation and Erosion Control is included in Section 01110.
F. Seeding is included in Section 02930.
1.03 SUBMITTALS
A. Submit in accordance with Section 01300 complete product data for materials specified in this Section.
1.04 REFERENCE STANDARDS
A. American Society for Testing and Materials (ASTM)
1. ASTM C33 – Standard Specification for Concrete Aggregates.
2. ASTM D698 – Standard Test Methods for Moisture-Density Relations of Soil and Soil-Aggregate Mixtures Using 5.5-lb (2.49 kg) Rammer and 12-in (305 mm) Drop.
3. ASTM D2487 – Standard Classification of Soils for Engineering Purposes (Unified Soil Classification System) (2006)
B. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.
1.05 QUALITY ASSURANCE
A. Laboratory Testing
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1. At least seven days prior to the placement of any backfill or fill materials, deliver a representative sample of the proposed materials weighing at least fifty pounds to the soils testing laboratory in accordance with Section 01410.
2. Engage the soils testing laboratory to perform:
a. Grain size, plasticity index, and liquid limit determinations of the samples to determine their suitability for use as backfill or fill material conformance to the materials requirements specified hereinafter.
b. The appropriate Proctor analyses to determine the maximum dry densities and corresponding optimum moisture contents required for compaction testing as specified elsewhere in the Contract Documents.
3. Test results and determinations of suitability shall be delivered to the Resident Project Representative no later than three days prior to the placement of backfill or fill materials.
PART 2 PRODUCTS
2.01 MATERIALS
A. Backfill and Fill materials shall be suitable excavated materials, natural or processed mineral soils obtained from off-site sources, or graded crushed stone or gravel. Backfill and Fill materials shall be free of all organic material, trash, or other objectionable materials which may be compressible or which cannot be properly compacted. Soft, wet, plastic soils which may be expansive, clay soils having a natural, in-place water content in excess of 30 percent, soils containing more than 4 percent (by weight) fibrous organic materials, soils having a plasticity index greater than 10, a liquid limit more than 50, a Standard Proctor (ASTM D 698) dry density of less than 100 pcf, and a percent by dry weight passing the No. 200 sieve greater than 35 percent shall be considered unsuitable for use as backfill and fill. Backfill and fill materials shall have a maximum of 1 percent expansion when testing is performed on a sample remolded to 98 percent maximum dry density (per ASTM D698) at 2 percent below optimum moisture content under a 100 lbs/sq ft surcharge.
B. Structural Fill shall be gravel, sandy gravel, or gravelly sand. Material shall have a plasticity index of less than 10 and shall conform to the following gradation limits:
Sieve Size Percent Finer by Weight
3-in 100 No. 4 20 - 70 No. 40 5 - 35 No. 200 0 - 35
C. Select Common Fill shall conform to the requirements of common fill except that the material shall not contain any materials larger than 1 1/-in largest dimension.
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D. Common Fill shall not contain granite blocks, broken concrete, masonry rubble, asphalt pavement, or any material larger that 3-in in any dimension. Common Fill shall have a plasticity index of less than 15 and shall conform to the following gradation limits:
Sieve Size Percent Finer by Weight
No. 40 83 No. 200 12
E. Screened Bedding Gravel shall be hard, durable, rounded, or sub-angular particles of proper size and gradation, and shall be free from sand, loam, clay, excess fines, and other deleterious materials. Screened bedding gravel shall be graded within the following limits:
Sieve Size Percent Finer by Weight
5/8 in. 100 in. 40 - 100 3/8 in. 15 - 45 No. 10 0 - 5
F. Sand for concrete, grout, and masonry shall conform to ASTM C33 for fine aggregate. General purpose sand shall be Select Common Fill.
PART 3 EXECUTION (NOT USED)
END OF SECTION
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SECTION 02270
EROSION AND SEDIMENTATION CONTROL
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor is responsible for implementing best management practices to prevent and minimize erosion and resultant sedimentation in all cleared and grubbed areas during and after construction. This Section covers the work necessary for the installation of structures and measures for the prevention and control of soil erosion. The Contractor shall furnish all material, labor and equipment necessary for the proper installation, maintenance, inspection, monitoring, reporting and removal (where applicable) of erosion prevention and control measures and to cause compliance with the General NPDES Permit for Storm Water Discharges from Construction Activities under this Section 02270.
1.02 RELATED SECTIONS
A. Site Preparation is included in Section 02100.
B. Trenching, Backfilling and Compaction is included in Section 02221
1.03 REFERENCES
A. CONTRACTOR shall be familiar with the following reference documents and keep those at the construction site at all times. These documents need to be complied with as applicable.
1. General NPDES Permit for Storm Water Discharges from Construction Activities (the NPDES Permit) and the Storm Water Control Act.
2. FDOT Standard Specifications for Road and Bridge Construction, 2010 edition.
3. National Stone Association, Aggregate Classification (the NSA Classification).
4. Erosion, Sedimentation and Pollution Control Plan (the Plan) as required by the NPDES Permit.
5. Comprehensive Monitoring Plan (the CMP) as required by the NPDES Permit.
1.04 DEFINITIONS
A. Engineer: For the purposes of this Section 02270, the term Engineer is synonymous with consulting engineer, licensed professional, designer, and consultant as used in permits, laws, rules, regulations, ordinances and other soil erosion and sediment control references. For the purposes of this Section 02270, the Owner may at any time during the project provide direction. This direction shall be considered equivalent to direction from the Engineer.
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B. Contractor: For purposes of this Section 02270, the term Contractor is synonymous with general contractor, discharger, operator, primary permittee and permittee (permit holder) as used in permits, laws, rules, regulations, ordinances and other soil erosion and sediment control references.
C. Qualified Personnel: For purposes of this Section 02270, the term Qualified Personnel means a person who has successfully completed an erosion and sediment control training and certification program approved by the Florida Department of Environmental Protection.
D. Other Definitions: Definitions as listed in the NPDES Permit, Part I, B. shall apply in this Section.
1.05 REGULATORY COMPLIANCE
A. Land disturbance activities are not authorized to begin until after all required erosion and sediment control permits are obtained from the United States, the State of Florida, and/or Lee County. Contractor is the Co-Primary Permittee and Operator under the provisions of the NPDES Permit. As such, Contractor will be required to sign certain certifications as described in the NPDES Permit. Contractor shall comply with requirements specified in the Contract Documents or by the Engineer. The Contractor shall also comply with all other laws, rules, regulations, ordinances and requirements concerning soil erosion and sediment control established by the United States, the State of Florida, and/or Lee County. The following documents and the documents referenced therein define the regulatory requirements for this Section 02270.
1. NPDES Permit: The Florida National Pollutant Discharge Elimination System (NPDES) General Permit for Storm Water Discharges Associated with Construction Activity governs land disturbance or construction activities of one (1) acres or more. On applicable sites, Contractor is responsible for complying with the terms and conditions of this permit.
1.06 SUBMITTALS
A. Contractor shall submit to the Engineer the proposed schedule for installation, maintenance and removal of all temporary and permanent erosion and sediment control measures. The schedule shall reflect the requirements of Paragraph 1.07 below (Sequence of Construction of Temporary Sediment Control Structures) and must show the anticipated starting and completion date for all land development activities including:
1. Installation of temporary and permanent sediment control structures
2. Stormwater management facilities,
3. Timber salvage operations,
4. Clearing operations,
5. Grubbing operations,
6. Rough and finished grading,
7. Building construction,
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8. Landscaping, including all seeding and sodding, and
9. Removal of temporary sediment control structures.
1.07 SEQUENCE OF CONSTRUCTION OF TEMPORARY SEDIMENT CONTROL MEASURES
A. Install all erosion and sediment control structures specified herein and shown in the Contract Documents, or as directed by the Engineer, as the first item of work within a given drainage area. Construction and installation of all sediment control structures shall begin downgradient of the area to be disturbed and proceed upgradient. Contractor shall at all times maintain all soil erosion and sediment control structures and practices throughout construction and until permanent grass cover is established.
B. Install additional erosion and sediment control structures as necessary to meet all regulatory requirements.
1.08 PAYMENT PROCEDURES
A. The unit price bid for work covered under this Section 02270 shall include the furnishing, placement, maintenance, and removal of the silt fence, hay bales, temporary dikes and ditches, sediment traps, sediment basins, construction exits and all temporary vegetative and non- vegetative ground cover and all earthwork, labor, materials, and equipment necessary to complete the work as specified or directed by Engineer.
PART 2 SPECIFIC REQUIREMENTS
The requirements specified herein and shown in the Contract Documents are minimum requirements for preventing or minimizing soil erosion and sediment transport. Contractor shall install and maintain soil erosion and sediment control measures in accordance with the ERP permit No. #######.
2.01 TEMPORARY SEDIMENT BARRIERS (SILT FENCE)
A. Install silt fence where shown on the Drawings or as directed by the Engineer.
B. Material Specifications: Filter fabric must meet the requirements set forth in Section 104 of the FDOT Standard Specifications for Road and Bridge Construction, 2010 edition. Contractor shall submit to Engineer copies of delivery invoices, certifications or other documentation that the filter fabric complies with these specifications if requested by Engineer.
C. Installation: In general, silt fencing shall be installed on the downgradient side of all areas to be disturbed as well as the perimeter of the project site (Engineer may authorize an exception for a perimeter which is upgradient from all land disturbing activity). All posts used to install silt fence shall comply with the specifications in the FDOT Standard Specifications. Posts must be placed at least 12 inches in the ground and cannot be more than 6 feet apart from one
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another. Fence fabric must be inserted below ground and fence fabric must be fastened to posts according to the specifications.
D. Maintenance: In accordance with Paragraph 3.01 below, all silt fencing shall be inspected and maintenance performed, if needed, within 24 hours of inspection once every seven (7) calendar days and within 24 hours of a rainfall event that has precipitation of 0.5 inches or greater. All silt fencing materials, including fabric, posts and fasteners must be replaced six months after installation. At the earlier of (1) every 14 calendar days, or (2) when sediment reaches a depth of one half the installed fence height, all soil, silt, sediment and other material captured by the silt fence should be removed and returned upgradient on the construction site. The silt fence shall be maintained such that it minimizes sediment transport as designed.
2.02 TEMPORARY SOIL EROSION STABILIZATION (VEGETATIVE)
A. This section covers work necessary for temporary stabilization of soil to prevent erosion following clearing, grubbing, grading or other construction activities in the areas identified in the Contract Documents or as directed by the Engineer, except wetlands. The right is reserved to modify the use, location, and quantities of the areas requiring stabilization as the Engineer considers being in the best interest of the Owner. During construction, the Engineer may designate the extent of stabilization used in each location throughout the project.
B. General Criteria: The stabilization measures specified herein shall be initiated on all disturbed areas including dikes and ditches within 24 hours of completion to minimize erosion and soil transport, provided however, that stabilization measures specified herein do not have to be initiated in the event that construction activities will resume on that portion of the site within fourteen (14) days from the date activities temporarily ceased. For cleared areas which may not receive permanent vegetative or other stabilization measure for six (6) months or less AND a suitable growing season is not available for seeding to establish an erosion retardant cover, mulch may be applied according to the specifications below.
C. Material Specifications: Seed shall be clean, delivered in original unopened packages and bearing an analysis of the contents. Guaranteed 95 percent pure with minimum germination rate of 85 percent. Seed mix shall be as shown on the design drawings. Fertilizer shall be used if directed by Engineer. Fertilizer shall be commercial, chemical type, uniform in composition, free-flowing, conforming to state and federal laws, and suitable for application with equipment designed for that purpose. Fertilizer shall have a minimum percentage of plant food by weight as the following: 10 percent nitrogen, 10 percent phosphoric acid, and 10 percent potash. Straw mulch shall be threshed straw of oats, wheat, or rye, free from obnoxious weed seeds or obnoxious weeds, or shall be clean hay. Average stalk length shall be 6 inches. Wood waste, asphaltic emulsion, or erosion control matting such as jute, excelsior, are also appropriate for temporary stabilization. Asphaltic emulsion shall be CSS-1 as manufactured by Chevron Asphalt Company or equal as approved by the Engineer..
1. Contractor shall submit to Engineer certificates of inspection of seed by state or federal authorities and copies of delivery invoices or other documentation of quantities of mulch and fertilizer.
2. The Contractor shall give at least 3 days notice to the Engineer of the time and place of starting the following operations:
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a. Delivery of materials
b. Planting of grass
3. The Contractor shall keep the Engineer advised of his schedule of operations.
D. Application: Planting and seeding shall be performed in accordance with the following schedule:
1. Summer Seeding: No earlier than April 1 and no later than October 15.
2. Winter Seeding: October 16 until weather conditions prohibit further construction operations as determined by the Engineer.
3. Soil Preparation: Prior to seeding operations, and after surface has been shaped, graded, and compacted, scarify surface to a minimum depth of 1 inch.
4. Seeding: All seedbeds shall be a minimum depth of 1 inch. Seedbeds shall be reviewed by the Engineer prior to seeding. For designated wetlands, reference seeding specification in Section 02930. After soil has been scarified, apply required seed mix, as specified in this section, uniformly with a cyclone seeder, drill, cultipacker seeder, or hydroseeder. When hydroseeding is the selected method of seeding, prepare and apply slurry at the rate and proportion specified below:
a. Seed Mix: 8 lbs/1,000 SF
b. Fertilizer: 30 lbs/1,000 SF
c. Water as necessary
The required fertilizer mix shall be uniformly applied at the time of seeding.
Upon completion of the seeding operations, apply straw mulch to a reasonably uniform thickness of 1-1/2 inches to 2-1/2 inches in depth. Mulch shall be loose enough to permit penetration of sunlight and air circulation, but dense enough to shade ground, reduce evaporation rate, and prevent or materially reduce erosion of underlying soil. Retain straw in place by applying asphaltic emulsion at a rate of 100 gallons per acre or mechanically tack the mulch into the soil to approximately 3 inches. Equipment used for tacking shall be specially designed for this use.
E. Application of Mulch Only: For areas to receive mulch only, apply at the following rates, to the following depths and according to the following specifications:
1. Dry Straw or Hay: Spread at a rate of two and one-half (2 1/2) tons per acre. Apply to a depth of six (6) to ten (10) inches. Apply uniformly and anchor as necessary.
2. Wood Waste: Spread at a rate of six (6) to nine (9) tons per acre. Apply to a depth of two to three inches. Apply wood waste only on slopes that are 3:1 or flatter. Anchoring is not
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necessary.
3. Jute Matting or Excelsior Netting: Apply in accordance with manufacturer’s recommendations.
4. Asphaltic Emulsion: Apply at a rate of 1200 gallons per acre. Apply uniformly.
F. Maintenance: In accordance with Paragraph 3.01, stabilized areas shall be inspected and maintenance performed, if needed, within 24 hours of inspection once every seven (7) calendar days and within 24 hours of a rainfall event that has precipitation of 0.5 inches or greater. Apply additional stabilization materials as needed.
PART 3 EXECUTION
3.01 INSPECTIONS AND MAINTENANCE
A. Contractor shall designate a Qualified Person to perform inspections required by this Section 02270. The following areas are to be inspected and maintenance performed, if needed, within 24 hours of inspection at least once every seven (7) calendar days and within 24 hours of a rainfall event that has precipitation of 0.5 inches or greater:
1. Disturbed areas of the construction site that have not undergone final stabilization.
2. Erosion and sediment control structures.
3. All locations where vehicles enter or exit the site.
4. Material storage and construction laydown areas that are exposed to precipitation and have not been finally stabilized.
B. In areas that have been finally stabilized, inspections and, if necessary, maintenance by Contractor will occur at least once per month for duration of contract or project, whichever is longer. Contractor shall maintain finally stabilized areas through the warranty period until final acceptance by the Owner.
C. During inspections, the following will be observed and appropriate maintenance procedures taken:
1. The conformance to specifications and current condition of all erosion and sediment control structures.
2. The effectiveness and operational success of all erosion and sediment control measures.
3. The presence of sediments or other pollutants in stormwater runoff at all runoff discharge points.
4. If reasonably accessible, the presence of sediments or other pollutants in receiving waters.
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5. Evidence of off-site sediment tracking at all locations where vehicles enter or exit the site.
An inspection checklist is included at the end of this section. This checklist must be completed during each inspection, dated and signed by the Qualified Person conducting the inspection. Completed inspection checklists shall be kept on-site with the Contract Documents and submitted to the Owner on a monthly basis. The Contractor will repair deficiencies within 24 hours of inspection.
3.02 MONITORING AND REPORTING
A. Monitoring: The Contractor shall cooperate with the Owner in the implementation of the Comprehensive Monitoring Program (CMP), which is an integral part of the Agreement.
B. Reporting: The Contractor shall cooperate with the Owner to submit a summary of the monitoring results to the EPD as required in the NPDES permit
3.03 REMOVAL OF TEMPORARY SEDIMENT CONTROL STRUCTURES
A. At such time that temporary erosion and control structures are no longer required under this Section 02270, the Contractor shall notify the Engineer of its intent and schedule for the removal of the temporary structures, and obtain the Engineer’s approval in writing prior to removal. Once Contractor has received such written approval from Engineer, Contractor shall remove as approved the temporary structures and all sediments accumulated at the removed structure shall be returned upgradient. In areas where temporary control structures are removed, the site shall be left in a condition that will restore original drainage.
3.04 NOTICE OF TERMINATION
A. When all construction activities have ceased, final stabilization has been implemented by the Contractor and the site is in compliance with the NPDES permit, the Contractor together with the Owner shall submit a Notice of Termination.
3.05 INSPECTION AND SAMPLING
A. During the life of this contract the Contractor shall be responsible for the inspection of all Erosion and Sedimentation Control devices. The Contractor shall immediately correct any deficiencies. Daily reviews of devices shall be made in areas where construction activities have changed the natural contour and drainage runoff to ensure that all devices are properly located for effectiveness.
END OF SECTION
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SECTION 02413
HORIZONTAL DIRECTIONAL DRILLING
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall furnish all labor, equipment, and materials necessary to install pipelines by horizontal directional drilling (HDD) at the locations shown on the Plans.
B. The Work of this section includes all labor, machinery, construction equipment and appliances required to perform in a good workmanlike manner all directional boring and carrier pipe installations for the subaqueous and road crossings as shown on the Contract Documents.
C. The directional boring scope shall include, but not be limited to steerable directional boring equipment, operator control cabin, mud plant, entry and exit pits, pumps, hoses, and other equipment, sheeting, location signs as required, miscellaneous appurtenances to complete the entire Work as shown on the Contract Drawings and restoration and disposal of waste products. Directional boring operations shall be performed within the right-of-way and/or easements shown on the Drawings.
1.02 RELATED WORK
A. Dewatering and Drainage is included in Section 02140.
B. Earthwork is included in Section 02200.
C. Support of Excavation is included in Section 02275.
D. Polyvinyl Chloride (PVC) Pressure Pipe is included in Section 02622.
E. High Density Polyethylene (HDPE) Pipe and Fittings is included in Section 02623.
1.03 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS
A. Installation of Pipelines by Horizontal Directional Drilling, Pipeline Research Committee, American Gas Association, PR-227-9424, April 1995.
B. Horizontal Directional Drilling Good Practices Guidelines, Latest Edition, HDD Industry Consortium, 300pp.
C. API Bulletin 13D, 1985. Bulletin on the Rheology of Oil-Well Drilling Fluids, Second Edition, Dallas, Texas, American Petroleum Institute.
D. API Recommended Practice 13B-1, 1990. Standard Procedures for Field Testing Water- Based Drilling Fluids, First Edition, Dallas, Texas, American Petroleum Institute.
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E. Installation of Pipelines Beneath Levees Using Horizontal Directional Drilling, US Army Corps of Engineers, Waterways Experiment Station, Final Report, CPAR-GL-98-1, April 1998.
F. API Specifications 13A, 1993. Specification for Drilling Fluid Materials, Fifteenth Edition, Dallas, Texas. American Petroleum Institute.
G. IADC Drilling Manual, 1992. Eleventh Edition, Houston, Texas, International Associated of Drilling Contractors.
H. Pressure Pipelines Design for Water and Wastewater, American Society for Civil Engineers, 2nd ed., 1992.
I. Tables for Hydraulic Design of Pipes and Sewers, American Society for Civil Engineers, 5th ed., 1990.
1.04 SUBMITTALS
A. Following is the summary of submittals required for the HDD Work:
1. Sheeting, shoring, and dewatering.
2. Pullback load calculation.
3. Pipe stress calculation.
4. Maximum allowable drilling fluid pressure calculation.
5. HDD Work Plan, including pilot hole drilling, reaming, and pullback procedures and rates; calculation of maximum drilling speed compatible with pump capacity and soil conditions; solid control plans; equipment and pipe layout areas; etc.
6. Contingency plans for remediation of potential problems that may be encountered during drilling operation.
7. Description of pipe internal cleaning, internal gauging, hydrostatic test, tracer wire test, etc.
8. Qualifications of superintendent and key personnel along with Florida/OSHA certification for Site Safety Representative.
9. Daily logs and records.
10. Shop Drawings.
11. Construction activity schedules.
12. Procedures and data records of downhole survey tool and tracking system.
13. As-built pilot bore profile.
14. Pipe filling and testing during pullback.
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15. Frac-out and surface spill contingency plan, which shall be reviewed by the Florida Department of Environmental Protection prior to construction.
16. Details of soil separation plan along with disposal of spoils and drilling fluids.
17. Details for the protection of adjacent utilities, structures, and facilities.
18. Health and Safety Plan.
19. Settlement Monitoring Plan.
B. In addition to other requirements indicated throughout this Specification, the following sections describe the submittals in more detail. Submittals shall be in accordance with the requirements of Sections 01170 and 01300 of the Specifications, providing sufficient detail to allow the Engineer to judge whether or not the proposed equipment, materials, and procedures will meet the Contract requirements. The Engineer’s review of submittal details and data will be based on considerations for the completed Work, utilities, and the possibility of necessary delays in the execution of the Work to be constructed under this Contract. Review and acceptance of the Contractor’s submittals by the Engineer shall not be construed in any way as relieving the Contractor of its responsibilities under this Contract.
C. Contingency Plans for Potential Problems: The Contractor shall submit contingency plans for remediation of potential problems that may be encountered during the drilling operations. The contingency plans shall address the observations that would lead to the discovery of the problem and the methods that would be used to mitigate the problem. Potential problems that shall be addressed include:
1. Loss of returns/loss of circulation of drilling fluids.
2. Inadvertent returns/hydrofracture or surface spills resulting in drilling fluids entering water or reaching the surface. Stand-by equipment shall be provided by the Contractor to recover fluids. Turbidity barriers shall be part of the stand-by equipment to minimize dispersion in the event that drilling fluids reach the surface.
3. Encountering obstruction during pilot bore or reaming/pullback.
4. Drill pipe or product pipe cannot be advanced.
5. Deviations from design line and grade exceed allowable tolerances.
6. Drill pipe or product pipe broken off in borehole.
7. Product pipe collapse or excessive deformation.
8. Utility strike.
9. Deviation from planned bore path.
10. Hydrolock occurs or is suspected.
11. Excessive ground settlement or heave.
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12. Coordination with tidal fluctuations.
D. Horizontal Directional Drilling Work Plan: Submit an HDD Work Plan complete with drawings and written description identifying details of the proposed method of construction and the sequence of operations to be performed during construction.
The Plan shall include a detailed plan and profile of the bores showing any proposed deviations from the drawings included in design documents and plotted at a scale no smaller than one inch equals 40 feet horizontal and one inch equals 5 feet vertical.
E. Qualifications: Submit written documentation of HDD superintendent and key personnel experience in accordance with Sections 1.07.A. and 1.07.B. Submit evidence of Florida/OSHA certification for the Site Safety Representative.
F. Daily Logs: The Contractor shall submit daily logs and records in accordance with Section 1.07.C. Daily logs and records shall be provided to the Engineer by noon on the day following the shift for which the data or records were taken.
G. The Contractor shall provide at least 72 hours written notice of the planned inspection of drilling activities as described in Section 1.07.D.
H. Shop Drawings:
1. The Contractor shall submit all Shop Drawings to the Engineer. All Shop Drawings shall be reviewed and accepted by the Engineer prior to Contractor’s mobilization. All Drawings shall be legible with dimensions accurately shown and clearly marked in English.
2. Drawings and photographs transmitted by a facsimile will not be accepted. The Drawings shall include the planned equipment, equipment setup areas, pipe layout areas, any excavations or mud recirculation pits.
I. Schedule: At least 15 days prior to mobilization, the Contractor shall submit a detailed schedule for each HDD installation showing all major construction activities and durations, with beginning and completion dates shown. The schedule shall be updated at least every two weeks or more frequency, as directed by the Engineer, and shall include:
1. “One Call” utility locate requests and visual confirmation of all crossing utilities and all parallel utilities within 10 feet laterally of the bore centerline.
2. Rig mobilization and setup.
3. Pilot bore drilling.
4. Pre-reaming and reaming.
5. Layout and thermal butt-fusing of pipe.
6. Pressure testing of pipe prior to pullback.
7. Final reaming and pullback of pipe.
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8. Pressure testing of pipe after installation.
9. Annulus grouting after installation.
10. Mandrel/pig test to confirm deformations of pipe are within allowable tolerances.
11. Cleanup, surface restoration, and demobilization.
J. Description of Methods, Equipment, and Materials: The Contractor shall submit detailed description of methods, equipment, and materials to be used for the pipeline installation. Descriptions of drilling fluid additives shall be accompanied by Materials Safety Data Sheets (MSDS) and Manufacturers’ descriptions and warranties. Descriptions of equipment shall include Manufacturers’ Specifications, calibrations, appropriate drawing, photographs, and descriptions of any modifications since manufacture.
K. Surveying, Equipment and Procedures: The Contractor shall submit records of equipment calibrations and certifications for all equipment used for downhole surveys and tracking of the drill head. Procedures for operating the downhole survey tools shall be described, including measures to verify the accuracy of the equipment readings.
L. Pipe Filling Methods: The Contractor shall submit methods and procedures for filling the pipe with fluid during pull back, testing, and annular space grouting.
M. Equipment Layout: The Contractor shall submit sketches depicting the layout and locations of equipment within the rig side work area and pipe side work area, including any proposed drilling fluid containment and recirculation pits. The Contractor shall confirm that all operations shall be completely contained within the temporary construction easement shown on the Plans.
N. Calculations for Pullback: The Contractor shall submit calculations for pullback loads for the conditions and operating practices anticipated.
O. Pipe Stress Calculations: The Contractor shall submit calculations for pipe stresses expected to result from the pullback, bending, fluid buckling loads, earth loads, groundwater loads, and any other installation and service loads expected to be exerted on the pipe. All assumptions used in the calculations, including the radius of curvature, assumed drilling fluid weights, whether pipe is assumed to be filled or empty during pullback, and temperature shall be provided.
P. Calculations of Maximum Allowable Drilling Fluid Pressure: The Contractor shall submit calculations identifying the critical downhole pressure that would cause hydrofracture or inadvertent drilling fluid returns. The calculations shall identify the critical points in the alignment beneath the channel and near the exit point where the soil cover above the bore is low. The calculations shall identify all parameters used and state all assumptions made in the calculations.
Q. Frac-Out and Surface Spill Contingency Plan: A Frac-out and Surface Spill Contingency Plan shall be prepared for the installation of pipelines using HDD. The Plan shall be submitted to the Engineer prior to construction. The Contractor shall submit letter signed by an authorized representative of Contractor, confirming that the Plan will be followed. If
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required by permit conditions, Contractor shall revise the Plan as necessary to satisfy the associated regulatory agency.
R. Rig Capacity: The Contractor shall submit details on the capacity of the drill rig verifying that the pullback capacity is greater than the required pullback calculated and submitted by the Contractor.
S. Soil Separation Plan: The Contractor shall submit details on the pump and cleaning plant. Include dimensions, Manufacturer’s Specifications, pump capacity, noise rating, and soundproofing details on the system.
1. Pump capacity should be specified for water at sea level elevation, and adjusted for actual elevation and fluid viscosity.
2. Provide details on the generator, including dimensions, noise ratings at 25 feet, and soundproofing. Confirm that the generator and other on-site equipment can be operated without exceeding the maximum allowable noise tolerances specified in permit. Contractor will need to know permit requirements at time of bidding.
T. Radius of Curvature: The Contractor shall confirm that the bore can be completed using the radius of curvature and geometry shown on the drawings along with the calculations showing that installation stresses do not exceed allowable pipe stresses.
U. Plans for Disposal of Spoils and Drilling Fluids: The Contractor shall submit Plans for disposal of waste materials resulting from the pipeline construction, including drilling fluids, cuttings, waste oil, fuel, discharge water, etc. The Contractor shall identify the disposal site and submit a letter indicating willingness and legal authority to accept the described and anticipated waste products.
V. Annular Space and Contact Grouting: The Contractor shall submit descriptions of methods, equipment, and materials to be used for annular space and contact grouting any areas where over-excavation, aborted bores, voids, or cavities are created or encountered.
W. Protection of Adjacent Structures and Facilities: Provide details on measures to be taken to monitor and protect adjacent utilities, structures, railroad tracks, roadways and sidewalks, and provide details on monitoring equipment and provisions, including the layout of all settlement points and other monitoring points. Provide two copies of pre-construction survey of adjacent structures and photographs with captions to document prior to beginning HDD construction.
X. Health and Safety Plan: The Contractor shall submit a Health and Safety Plan, including the name of the Contractor’s Site Safety Representative, emergency telephone numbers for medical facilities, and precautions for handling and disposal of any hazardous or flammable materials. The Health and Safety Plan shall include a code of safe practices and an emergency plan in accordance with OSHA requirements.
Y. Settlement Monitoring Plan: The Contractor shall submit a settlement monitoring plan showing location of proposed settlement points and frequency of readings.
Z The following shall be submitted as construction progresses and at the completion of construction.
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1. Daily Logs and Records: The Contractor shall submit complete, legible, written daily logs and records as called for in Section 1.07.C of this Section and as directed by the Engineer, by noon of the following day to which the records correspond.
2. Variations in Plan and Profile: The Contractor shall document any variations between the actual Plan and profile of the bore path and the location shown on the Plans. The Contractor shall notify the engineer immediately upon discovery of any deviations.
3. Mud Weights: The Contractor shall submit measured mud and/or drilling fluid weights used during pilot boring and reaming of the bore measured at a minimum of twice per shift or at least once per 200 feet of drilled or reamed length, whichever is more frequent.
4. Submit maximum drilling and reaming rates for pilot bore and each reaming pass and confirm that pump capacity is adequate for these anticipated drilling rates for the drilling fluid weights and viscosities anticipated.
5. Pressure Test Records: The Contractor shall submit all pressure test records for both the pre-installation and post-installation tests.
6. Pilot Bore As-Built Profile: The Contractor shall submit an as-built profile of the pilot bore within 24 hours of completion of the pilot bore.
1.05 DEFINITIONS
A. Annular Space: The space between the excavated HDD final reamed bore diameter and the product pipe or cable.
B. Bent Sub: A bent sub is a section of drill pipe behind the cutting tools that is inclined at an angle at one to three degrees from the axis of the bore in the desired direction of steering. The bent sub allows steering while rotating the cutting tools.
C. Horizontal Directional Drilling: HDD is a surface-launched, guided, steerable drilling system used for the trenchless installation of pipes, conduits, and cables. A pilot bore path is excavated in a shallow arc from a surface-launched drill rig. Excavation takes place with fluid assisted cutting from a drilling tool on the drill string. The pilot bore is directed by the positioning of a bent sub. Tracking of the drill string is achieved by using a downhole wireline survey tool which may be augmented by using an energized wire grid at the surface. The bore is filled with drilling mud/fluid for stabilization, to cool the cutting tools, and to mix the cuttings into a slurry, which is circulated to the entry point where solids are removed before the drilling fluids are returned to the bore. The bore path is enlarged with subsequent reaming passes until the desired diameter is achieved. The product pipe, conduit, or cable is then pulled into the fluid-stabilized bore hole.
D. Drilling Fluid/Mud: A mixture of water, bentonite, and/or polymers continuously pumped to the drilling tools to facilitate the removal of soil cuttings, and stabilization of the bore. These fluids also cool the cutting tools and lubricate the drill pipe and product pipe string.
E. Pilot Bore: The action of creating the first guided pass of the HDD process which is then reamed in one or more passes to the size required to allow pullback of the pipe or casing.
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F. Drilling Tool/Bit: Any tool or system of tools which excavates at the face of a bore.
G. Pullback: The part of a horizontal directional drilling process in which the drill pipe, swivel, and product pipe or cable is pulled back through the bore to the entry.
H. Pullback Loads: The loads (forces) applied to a drill string and product pipe during the pullback process. In addition to the tensile pullback loads, bending, buckling and combination loads must be considered in design.
I. Obstruction: Any hard object lying completely or partially within the design pathway of the bore and pipeline that prevents further advancement of the drill pipe, pre-reamer, reamer, and/or pipe, after all reasonable Contractor attempts to advance past the object or re-drill around the object have failed.
J. Settlement Point: A point with elevation and spatial location established by survey prior to construction. The point is re-surveyed periodically to monitor ground movements. The point may be a nail, pin, subsurface settlement rod, borehole extensometer, or other device that can be readily located and surveyed.
K. HDD Work Plan: Written descriptions, together with sketches, drawings, schedules, and other documents defining Contractor’s plans and procedures for horizontal directional drilling.
1.06 PERFORMANCE REQUIREMENTS
A. Equipment: The Contractor shall provide all equipment, materials, and personnel necessary for completing the installation as shown on the Plans and specified herein. The equipment and materials shall include but are not limited to:
1. Directional drilling rig with all ancillary equipment, including drill pipe, drilling fluid, cutting tools, reaming bits, swivels, expanders, motors, pumps, hoses, mixing equipment, drilling fluid processing equipment (cuttings separation equipment), downhole survey equipment, energized surface grid tracking system, fluid pressure and flow rate monitoring equipment, spare parts, pipe handling equipment (cranes, backhoes, rollers, side boom tractors) control equipment, and office equipment.
2. Drilling fluids, water, fuel, lubricant, polymers, or other additives.
3. Any other expendable or reusable materials, supplies, and equipment needed for the installation.
B. The drilling equipment shall be capable of advancing through the geologic conditions to be encountered at the site, as described in the geotechnical reports, and as anticipated by the Contractor.
C. The drilling fluid shall be designed for the coastal geologic and potentially saline conditions to be encountered at the site, as described in the geotechnical reports and as anticipated by the Contractor.
D. The drilling system shall include a fluid pump and separation plant that can achieve the rates of drilling fluid pumping, spoil separation, and slurry cleaning required by the
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Contractor to achieve planned production rates for the soils described in the geotechnical reports, and as anticipated by the Contractor. Shaker screens and hydrocyclones may be required for efficient separation of spoils. The Contractor is advised that the separation plant must fit within the allowable Work areas shown on the Plans.
E. All spoil and slurry must be contained in trucks, tanks, approved recirculation pits, or other containers at all times. Dumping of spoil or slurry on the ground, discharge into sewers, or discharge into the water bodies will not be permitted. All spoils will be transported and disposed of off-site at an approved disposal facility that meets all State of Florida and local requirements.
F. Perform all Work within work areas shown on the Plans.
G. The pipeline shall be installed using the radii of curvatures and entry and exit angles shown on the drawings, unless deviations are approved in writing by the Engineer through the submittal process.
H. Pipe rollers and lifters will be required to help the transition of the carrier pipe into the bore. The number of pipe rollers and lifters shall be determined by the Contractor and submitted as part of the Work Plan.
I. Surface settlement or heave of utilities and other features above the HDD centerlines and within the zone influenced by the HDD construction shall be limited to values that avoid damage. Zero settlement is allowed for paved road crossing. The Contractor shall repair any damage resulting from settlement or heave caused by HDD activities at no additional cost to the Owner. The Contractor shall grout any voids caused by or encountered during drilling.
J. Safety: It shall be the Contractor’s sole responsibility that all Work is done in conformance with all applicable federal, state, and local safety requirements. Required safety equipment and procedures shall be employed by the Contractor at all times.
K. Pipe: The pipe will be certified by the Contractor as meeting all requirements of the Specifications. The fabricated pipe will be pressure-tested by the Contractor prior to pullback and after installation is completed.
L. The Contractor shall allow access to the Engineer and shall furnish necessary assistance and cooperation to aid the Engineer in observations and data and sample collection, including, but not limited to the following:
1. The Owner and/or Engineer shall have full access to the operator control container prior to, during, and following all HDD operations. This shall include, but not be limited to, providing visual access to real-time operator control screens, gauges, and indicators.
2. The Owner and/or Engineer shall have full access to the slurry separation plant prior to, during, and following all HDD operations. This shall include, but not be limited to, full access to shaker screens, hydrocyclones, conveyor belts, and slurry and spoil holding tanks. The Engineer shall be allowed to collect soil samples from the shaker screens and/or spoil holding tanks on the slurry separation plant a
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minimum of once per installed pipe section, and whenever changes in conditions are observed or suspected.
M. Contractor shall comply with all local noise ordinances. Sound levels in excess of these values are sufficient cause to have the Work halted until equipment can be quieted to these levels. Work stoppage for excessive noise shall not relieve the Contractor of the portions of this Section including, but not limited to completion of all Work within specified Contract Time and Contract Price. The Contractor shall submit a Plan prior to construction identifying all noise reduction/abatement procedures. The Plan will be reviewed by the Engineer prior to construction.
If mufflers cannot achieve the necessary noise reduction, noise abatement shall be accomplished by the Contractor’s installation of baffles (or other acceptable means) positioned to break line-of-sight from the noise source to affected residences and/or commercial structures. Minimum noise abatement measures shall consist of equipping all engines with hospital grade mufflers or silencers.
1.07 QUALITY ASSURANCE
A. Contractor Qualifications and Experience: The Contractor shall have successful experience installing pipelines using the horizontal directional drilling process on at least three projects with similar diameters, installation lengths, and ground and groundwater conditions. Contractor must be licensed in the State of Florida as an underground utility contractor for a minimum of 4 years. Contractor shall demonstrate experience of monitoring downhole annular pressures during HDD operations on at least three projects. The Contractor shall furnish evidence of successful experience, including project owner, project name, location, diameter, length, depth, ground conditions, any problems encountered and how resolved, and any claims and how resolved. The project owner’s representative with address and telephone number shall be provided. Alternatively, the Contractor shall provide copy of a letter from the project owner, confirming that Contractor has met pre-responsibility criteria determination for this project.
B. Qualifications and Experience of Contractor Personnel: The Contractor shall employ skilled, experienced superintendent(s) and personnel. The superintendent(s) shall have successful experience using the HDD process, on at least three projects with similar diameters, pullback length, and ground conditions. The Contractor shall furnish resumes of the superintendent(s) and key personnel. Personnel experience records should include project names, locations, pullback lengths, ground conditions, pipe materials, project description, project owner, engineer, and references with names, addresses, and telephone numbers. The superintendent listed in the submittal shall be on site during all construction related activities required for the HDD installation.
C. Daily Logs and Records: Daily logs and records shall be maintained by the Contractor and shall include tidal records, drilling lengths, location of drill head, drilling fluid pressures and flow rates, drilling fluid losses, inadvertent returns, drilling times required for each pipe joint, any instances of retraction and re-drilling of the pilot bore or segments thereof, and any other relevant observations, including any observed settlement, heave, frac-outs, or surface spills. The downhole annular drilling fluid pressures shall be measured and recorded throughout the pilot hole drilling. These records shall be maintained and provided daily to the Engineer. he position of the drill head shall be continuously tracked and recorded by a downhole wire line tracking locator system, and shall be supplemented by a
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“TruTracker” or equivalent tracking system installed between the entry point and the exit point. The coordinates of the surface wire grid system shall be surveyed and recorded. A plot of actual locations of the bore path shall be maintained and updated daily, or more frequently, as directed by the Engineer.
D. Advance Notices and Inspections: The Contractor shall provide at least 72 hours advance written notice to the Engineer of the planned inspection of major drilling activities, including pilot bore launch, pre-reaming, reaming, and pipe pullback. The Contractor shall immediately notify the Engineer, in writing, when any significant problems are encountered or if ground conditions are considered by the Contactor to be materially and significantly different than those represented with the Geotechnical Report. All Work by the Contractor shall be performed in the presence of the Engineer, unless Engineer grants prior written approval to perform such Work in Engineer’s absence.
E. Surveying Equipment and Procedures: All surveying equipment used for downhole surveying and tracking of the bore path and drill head shall be inspected and calibrated by the equipment Manufacturer prior to use. Proof of this inspection and calibration shall be provided to the Engineer prior to commencement of drilling operations.
PART 2 – PRODUCTS
2.01 PIPE
A. As described in Paragraph 1.1.A., the Contractor shall provide and install carrier pipe in accordance with the applicable pipe material Section.
B. The pipe thickness must conform to the most conservative design with respect to design calculations for the critical combination of internal and external pressure, pullback, and bending. The carrier pipe selected will meet the dimension ratio (DR) specified in their respective Section.
2.02 WATER
The Contactor shall secure a suitable source of water, and shall be responsible for transporting, storing, and disposing of any water required.
2.03 DRILLING FLUIDS
The Contractor shall select drilling fluid mixture combatable with ground salinity and chemistry and proportions to ensure continuous circulation, bore stability, reduce drag on the pipe, and completely fill the annular space between the bore and the pipe to control settlement. Management and disposal of drilling fluids shall be the Contractor’s responsibility. Drilling fluids shall not be disposed of on-site or discharged to sanitary or storm sewers, or the water way.
2.04 DRILL PIPE
The Contractor shall provide high quality drill pipes that have been inspected and determined to be adequate for the project requirements. Bent, racked, or fatigued drill pipes shall not be used. Threads must be in good condition. The length of each drill pipe shall be measured and recorded.
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2.05 TRACER WIRE
The Contractor shall provide a minimum 12-gauge composite tracer wire secured to the carrier pipe to aid in locating the pipe for maintenance purposes. The wire shall be composed of a solid steel core with copper cladding and HDPE insulation. The wire shall be secured to the carrier pipe at a maximum of 5-foot intervals by duct tape or other means selected by the Contractor to ensure the tracer wire is not damaged during the pipe installation process through the directional drill. The wire shall be terminated at grade within the nearest main line valve box location on each side of the directional drill. Tracer wire shall be DuraTrace DD or equal.
PART 3 - EXECUTION
3.01 GENERAL
A. The Contractor shall provide adequate control of surface water and drilling fluids drainage and runoff, and provide silt fences, hay bales, and wattles to prevent surface water or drilling fluids from being transported off-site.
B. The Contractor shall not initiate HDD until all submittals are received, reviewed, and accepted by the Engineer.
C. The Contractor shall not initiate HDD until all required permits are obtained.
D. It is the Contractor’s responsibility to provide barricades, fencing, or other safety measures to prevent public access into Work and staging areas.
3.02 PROTECTION OF UNDERGROUND UTILITIES
A. The drawings show existing buried utilities that are believed to be near the directional drill alignment. There is no guarantee that these utilities are located as shown or that other utilities are not present. It will be the Contractor’s responsibility to locate all nearby utilities or other potential subsurface obstructions that may interfere with the Work.
B. The Contractor shall notify “One Call” system to request marking of utilities that subscribe to One Call, and shall individually notify all other known or suspected utilities to request marking of these utilities. The Contractor shall confirm that all requested locates are made prior to commencing drilling operations. Contractor shall make all diligent efforts to locate any unmarked or abandoned utilities using all available information, maps, and drawings. The Contractor shall visually confirm and stake all existing lines, cables, or other underground facilities including exposing all crossing utilities and utilities within 10 feet laterally of the centerline of designed drilled path.
C. The Contractor shall control drilling practices to prevent damage to existing utilities.
D. The Contractor shall be responsible for all losses and repairs occasioned by damage to underground utilities resulting from drilling operations.
E. The Contractor shall make diligent effort to locate surface evidence of any other potential subsurface obstructions, such as piers and piles.
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3.03 WORK STAGING AREA
A. Work Staging: The Contractor shall limit staging and Work operations to the areas shown on the Plans, or as otherwise accepted in writing by the Engineer, for storage of equipment and materials, parking, pipe layout, drilling, and other Work.
B. Construction Impacts: The Contractor shall maintain the Work area in a manner that shall minimize adverse impacts on other public use activities. The Contractor shall proceed with Work in a safe, orderly manner, while maintaining the Work site free of debris and unnecessary equipment and materials.
C. Control of Drilling Fluids: The Contractor shall follow all requirements of the Frac-Out and Surface Spill Contingency Plan as submitted and approved and shall control operational pressures, drilling mud weights, drilling speeds, and any other operational factors required to avoid hydrofracture fluid losses to formations, and control drilling fluid spillage. This includes any spillages or returns at entry and exit locations or at any intermediate point. All inadvertent returns or spills shall be promptly contained and cleaned up. The Contractor shall maintain on-site mobile spoil removal equipment during all drilling, pre-reaming, reaming, and pullback operations and shall be capable of quickly removing spoils. The Contractor shall immediately notify Engineer of any inadvertent returns or spills and immediately contain and clean up the return or spill.
D. Combustible Materials: Combustible materials (fuel, oil, lubricants, etc.) shall be stored off-site or in a well-ventilated storage facility removed from the immediate vicinity of the drilling area by at least 20 feet.
E. Temporary Lighting: The Contractor shall procure and maintain all temporary lighting needed for Contractor’s operations, safety, testing, and inspection. Temporary lighting shall be removed after completion of construction.
F. Barricades, Warning Signs, and Lights: The Contractor shall, in accordance with approved Traffic and Safety Plans, erect appropriate barriers, warning lights, and signs, painted with approved colors, warnings, and graphics to ensure adequate warnings to personnel and the public.
G. Site Security: The Contractor shall install an enclosure fence around the Work area. The enclosure fence shall be adequate to prevent entry of unauthorized persons.
H. Removal of Temporary Facilities: At the completion of construction, the Contractor shall remove all temporary facilities installed by the Contractor. Unused soil, aggregate, and other materials shall be removed and disposed of at approved sites in accordance with Federal, State, and Local regulations. Any damage to streets, lawns, common areas, and sidewalks shall be restored to original or better conditions. All disturbed areas shall be re- vegetated.
3.04 MOBILIZATION
The Contractor shall mobilize all equipment, materials, and personnel necessary to construct the carrier pipeline using the HDD process at the locations shown in the Drawings.
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A. Entry Area: The Contractor shall set up temporary workspace within the areas delineated in the ROW on the Plans. Appropriate precautions and measures shall be employed by the Contractor to prevent erosion, surface drainage, and spillage of drilling fluids or other materials that could adversely impact the environmental quality of the site. Silt fences, hay wattles, and hay bales shall be used to line the Work area to minimize erosion and contain any spillage or runoff. Shovels, brooms, buckets, and barrels shall be kept on-site to facilitate containment and cleanup.
1. The Contractor shall be responsible for the cleanup and removal of drilling fluid lost during drilling operations. At a minimum a vacuum truck or trailer unit will be on standby and capable of responding within one hour to any spill or inadvertent return incident.
B. Exit Area: The exit area shall have a drilling fluid pit for containing drilling fluids and cuttings. Hay bales or wattles shall be used to line the exit area to minimize erosion and runoff. Containment and cleanup equipment shall be available to contain and clean up any surface spills and frac-outs.
C. Pipe Layout Area: Layout area shall be free of stones, wood, debris, and obstructions. Pipe rollers shall be provided by the Contractor to facilitate pipe pullback.
3.05 HORIZONTAL DIRECTIONAL DRILLING
A. Drill Rig Capacity: The capacity of the directional drilling system used by the Contractor shall be adequate to install the specified pipeline.
B. Pump Capacity: The pumps used by the Contractor shall be adequate to supply the required flow rate and pressures at the anticipated drilling fluid viscosity at all times. Drilling speeds shall not exceed pump capacity.
C. Bore Tracking and Monitoring: At all times during the pilot bore the Contractor shall provide and maintain a bore tracking system that is capable of accurately locating the position of the drill head in the x, y, and z axes. The Contractor shall record these data at least once per drill pipe length.
1. Downhole and Surface Grid Tracking System: Contractor shall monitor and record x, y, and z coordinates relative to an established surface survey benchmark, from downhole survey data using downhole wireline system. Tru-tracker energized surface grid, or equivalent, shall be installed and used to supplement the wireline system. The grids shall be surveyed to establish horizontal and vertical position to 0.1 feet accuracy. The data shall be continuously monitored and recorded at least once per drill pipe length.
2. Deviations between the recorded and design bore path shall be calculated and reported on the daily log. If the deviations exceed tolerances specified elsewhere, such occurrences shall be reported immediately to the Engineer. The Contractor shall undertake all necessary measures to correct deviations and return to design line and grade.
3. Drilling Fluid Pressures and Flow Rates: Drilling fluid pressures and flow rates shall be continuously monitored and recorded by the Contractor. The pressure shall
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be monitored at the pump. These measurements shall be made during pilot bore drilling, reaming, and pullback operations.
4. Drilling Speeds: Maximum allowable drilling speeds shall be calculated by the Contractor for pilot boring and each reaming pass and shall not be exceeded for pilot boring or reaming passes. Measurements shall be taken every 30 feet or 30 minutes, whichever is more frequent.
5. Drilling Fluid Viscosity and Density (Mud Weight): The Contractor shall measure and record drilling fluid viscosity and density at least three times per shift with at least 2 hours between readings, using calibrated Marsh funnel and mud balance. These measurements shall be included in daily logs submitted to the Engineer. The Contractor shall document modifications to the drilling fluids, by noting the types and quantities of drilling fluid additives and the dates and times when introduced. The reason for the addition of drilling fluid additives or other modifications shall be documented and reported.
D. Location of Entry and Exit Points: Entry and exit points shall be as shown on the Drawings, unless otherwise approved in writing by the Engineer. The Contractor shall employ licensed, experienced surveyors to locate the entry and exit points, and to establish horizontal and vertical datum for the bore and the pipe layout and fabrication areas.
E. Entry and Exit Angles: Drill entrance and exit angles shall be as shown on the Contract Plans and Drawings, unless otherwise approved in writing by the Engineer through the submittal process.
F. Pilot Bore: The pilot bore shall follow the design path of the bore shown on the Drawings.
1. Horizontal and Vertical Tolerances: Horizontal and vertical deviations shall be less than plus or minus 2 feet from the design path centerline. The Contractor shall continuously monitor horizontal and vertical position and record the position at least once per drill pipe length.
2. Radius of Curvature: The radius of curvature shall not be less than that shown on the Drawings unless otherwise approved in writing form the Engineer. The radius of curvature shall be calculated over the distance of three drill pipe sections.
3. Entry and Exit Tolerances: The location of the entry and exit points shall be as shown on the Drawings. The Contractor shall be solely responsible for all Work necessary to correct excessive deviations from line and grade, including redrilling, redesigning connections, and acquiring additional easement, at no additional cost to the Owner and without schedule extension.
G. Pre-reaming and Reaming: The pilot bore shall be pre-reamed and reamed using equipment and methods submitted by the Contractor. The Contractor shall completely pre- ream the bore to the final diameter prior to pullback.
H. Hydrostatic Pretest: The Contractor shall perform hydrostatic water pressure test in accordance with the applicable pipe material Section prior to pipe pullback.
I. Pipe Pullback:
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1. The pipe shall be installed by pulling it into the reamed bore path in a continuous operation, behind a final reaming tool selected by the Contractor.
2. The pipe shall be isolated from excessive torsional and axial stresses by a swivel device.
3. All measurements shall be made, recorded, and submitted on the daily logs during final reaming and pipe pullback.
4. Pulling Loads: The maximum pull (axial tension force) exerted on the carrier pipelines shall be measured continuously and limited to the maximum allowed by the pipe Manufacturer so that the pipe or joints are not overstressed. A factor of safety over the manufacturer’s maximum allowable is not required.
5. Pipeline Support: The pipelines shall be adequately supported during installation so as to prevent overstressing or buckling. The Contractor shall provide adequate support/rollers along the stringing area to support the required length of the carrier pipe for each bore. Such support/rollers shall be spaced at a maximum of 60 feet on centers, and the rollers be comprised of a non-abrasive material arranged in a manner to provide support to the bottom and bottom quarter points of the pipeline allowing for free movement of the pipeline during pullback. The pipe layout area shall be cleared of all large stones, construction debris, or other foreign objects that could damage the piping during pullback.
6. The leading end of the pipe shall be closed during the pullback operation.
7. Each length of pipe shall be inspected and cleaned as necessary to be free of debris immediately before joining.
8. Tracer wire will be attached to the leading end of the pipe pulling head and shall extend the full length of the installed pipe.
9. The Contractor shall at all times handle the carrier pipe in a manner that does not overstress or otherwise damage the pipe. Vertical and horizontal curves shall be limited so that wall stresses do not exceed 50% of yield stress for flexural bending of the carrier pipe. If the pipe is buckled or otherwise damaged due to Contractor’s acts or omissions, the damaged section shall be removed and replaced by the Contractor at his expense. The Contractor shall take appropriate steps during pullback to ensure that the carrier pipe and tracer wires will be installed without damage.
10. The carrier pipe shall be filled with water as it enters the bore to reduce pullback loads and to ensure that adequate internal pressure is maintained at all points to counter balance collapse pressures.
11. The Contractor shall monitor and inspect pipe rollers and method for suspending pipe at entry during the pullback operation to avoid damage to the pipe.
12. The Contractor shall cease operations if the pipe is damaged and shall remove the pipe from the bore and repair the pipe using the Manufacturer’s recommended procedure or replace the damaged pipe before resuming installation.
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13. Damage to the pipe resulting from installation, contact grouting, or grouting of the annulus is the responsibility of the Contractor, including costs for replacement and labor and materials. To confirm no damage to the pipe, upon completing of pullback and grouting, the Contractor shall perform the following test on the completed pipeline:
A sphere or pig, one inch less in diameter than the internal diameter of the product pipe, which is capable of allowing water to pass through it, complete with a pulling cable on either side of sphere or pig, shall be pulled through the entire length of the pipeline. If the pig or sphere cannot pass through the pipe, it shall be considered collapsed and damaged. Check Manufacturer’s tolerance and fuse bead size.
14. After the carrier pipe is completely pulled through the bore, a relaxation period of 48 hours or longer is recommended by the pipe manufacturer shall be provided before the final pipe tie-in.
15. Final Hydrostatic Test: The Contractor shall conduct a final hydrostatic test of the installed pipeline. Final test shall be in accordance with the applicable pipe material Section. The Contractor shall repair any defects discovered during the test, and repeat until the pipe passes the test.
J. Annular Space and Contact Grouting: The Contractor shall grout the annular space between the bore and the outer diameter of the carrier pipe prior to the mandrel or pig test described in 3.05.I.13 of this section. Grouting shall be completed within 48 hours of completion of the final hydrostatic test. Grouting procedures shall be in accordance with approved submittals. The grouting operations shall ensure that the annulus is filled with grout for at least the first 15 feet from entry point and the last 15 feet before exit point. Grouting may be accomplished using one or more of the methods described below, or an alternative submitted by the Contractor, subject to Engineer’s approval. The Contractor shall ensure that the annulus does not provide a preferential pathway for seepage regardless of the method(s) used and shall ensure that settlements shall not cause damage to existing utilities, roadways, or structures.
1. Tremie pipe. Tremie pipes shall be inserted into the borehole from both entry and exit ends after the pipe pullback is completed to grout the annular space between borehole and pipe, or any other voids created or encountered above the borehole. Tremie grout pipes shall be not less than 1-1/4 inch and not more than 2-inch diameter Schedule 40 PVC, and shall be inserted at the crown and at two locations 60 degrees from the crown. Grout will be injected in sufficient volume to completely fill the annulus as the tremie pipes are withdrawn. Grouting pressures shall be carefully controlled and monitored to avoid applying excessive pressure to the pipe and to avoid heave or hydrofracture. The pipes shall be filled with water during grouting to counterbalance grouting pressures and to avoid excessive heat of hydration as the grout sets that could damage the pipes.
2. Mix grout into drilling fluids and inject with drilling fluid as pipe is pulled back final 15 feet to grout annulus at entry side. Grout shall be mixed into drilling fluid recirculation/distribution system and shall be injected as drilling fluid as pipe is pulled back final 15 feet. The grout mixture shall satisfy performance requirements of drilling fluid before set and requirements of annulus grout after set. Retarding agents may be incorporated into grout mixture to allow sufficient time to complete
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pipe pullback before initial grout set. The exit side annulus shall be grouted by inserting a tremie pipe into the bore annulus as described in J1 above. Grout/drilling fluid injection pressures shall be less than pressures that could result in collapse of the pipe or hydrofracture of the surrounding soil.
K. Obstructions: The Contractor shall notify the Engineer immediately in the event that any obstruction is encountered that prevents further advancement of the drill pipe, or pullback of the pre-reamer, reamer, and/or pipe. The Contractor shall make all diligent and reasonable efforts to advance past the object by drilling slowly through the object, pulling back, and drilling along a new bore path that avoids the object, or excavating and exposing and removing the object, and all other reasonable attempts to continue the bore. The Contractor shall notify the Engineer or proposed measures to attempt to advance past the object, prior to initiating the attempt. If the Contractor attempts to pullback and re-drill, the Contractor shall adhere to line and grade tolerances established in this Section, unless the Engineer approves variance, in writing, prior to the Contractor’s attempt to re-drill. The Contractor and Engineer shall investigate the cause and together determine an appropriate response. Appropriate response may include revisions to equipment or methods, retraction and re-drilling of a portion of the bore, or abandonment of the hole. If abandonment is deemed necessary, the Contractor shall recover, to the extent practicable, any drill pipe, product pipe, and tools in the bore, and properly abandon the bore by contact grouting unless otherwise directed in writing by the Engineer. If the bore is abandoned, the Contractor shall be allowed to begin a second attempt to install the pipeline at an alternate location subject to approval, in writing, by the Engineer. The Contractor shall take all reasonable actions to complete the installation with minimal delays.
L. Site Restoration and Demobilization: The Contractor shall remove all equipment, materials, drilling fluids, muck, waste, and debris from the site and restore the site to its original condition upon completion of the installation. Restoration and demobilization shall be completed by the Contractor within 7 days of the completion of the pipeline installation.
M. Settlement Monitoring: The Contractor shall visually monitor for settlement or heave before and during drilling and grouting operations.
END OF SECTION
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SECTION 02515
SIDEWALKS, DRIVEWAYS AND CURBS
PART 1 GENERAL
1.1 SUMMARY
A. Section Includes: Sidewalks, sidewalk ramps, driveways, curbs and drive approaches complete with concrete materials, concrete curing compounds, joint materials, field quality control and appurtenances.
1.2 REFERENCES
A. Reference Standards: Conform the work for this Section to the applicable portions of the following standard Specifications.
1. ASTM - American Society of Testing and Materials 2. AASHTO - American Association of State Highway Officials and Transportation Officials 3. FDOT - Florida Department of Transportation - Standard Specifications for Road and Bridge Construction. 4. FAC - Florida Accessibility Code. 5. ADAAG - American with Disabilities Act Accessibility Guidelines 6. UFAS - Uniform Federal Accessibility Standards
1.3 SUBMITTALS
A. Reports: Written permission for the use of all local disposal sites Furnish copies to the ENGINEER.
B. Test Reports:
1. Thickness and Compressive Strength: Provide the ENGINEER with two (2) certified copies of the test results. Perform the tests by a laboratory approved by the ENGINEER.
1.4 JOB CONDITIONS
A. Environmental Requirements:
1. Temperature: Comply with the requirements for concrete installation due to outside ambient air temperatures as specified under Article 3.3.1 of this Section.
B. Protection:
1. Protection Against Rain: Comply with the requirements for protecting new work against damage from Rain, as specified under Article 3.3.1 of this Section.
2. Protection Against Cold Weather: Comply with the requirements for protecting new work against damage from cold weather, as specified under Article 3.3.1 of this Section. 5000-79695 02515-1 Florida Governmental Utility Authority Waterway Estates Interconnect 60% Submittal
PART 2 PRODUCTS
2.1 MATERIALS
A. Concrete: Use 2,500 psi concrete except as modified herein.
B. Ready-Mixed Concrete: Use ready-mixed concrete which conforms to ASTM C94, Alternate 2.
C. Water: Use water for mixing and curing concrete reasonably clean and free from oil, salt, acid, alkali, chlorides, sugar, vegetable, or other substances injurious to the finished product. Waters from sources approved by the local Health Department as potable may be used without test. Test water requiring testing in accordance with the current Method of Test for Quality of Water to be Used in Concrete, AASHTO T-26.
D. Concrete Curing Compounds: Use white membrane curing compound for curing concrete which conforms to AASHTO M148, Type 1 clear, or Type 2 while per FOOT Section 925.
E. Premolded Joint Filler: Use fiber joint filler which conforms to ASTM 01751. Use filler of the thickness, as specified herein, or as directed by the ENGINEER.
F. Steel Hook Bolts: Use hook bolts which conform to ASTM A 706, or for Grade 60 of ASTM A615, A616, or A617. Use 5/8-inch diameter hook bolts self tapping.
G. Joint Sealant: Use hot-poured type joint sealant which conforms to ASTM 01190.
PART 3 EXECUTION
3.1 CONTRACTOR'S VERIFICATION
A. Excavation and Forming: Prior to the installation of any concrete, examine the excavation and forms for the proper grades, lines, and levels required to receive the new work. Ascertain that all excavation and compacted subgrades are adequate to receive the concrete to be installed.
1. Correct all defects and deficiencies before proceeding with the work.
B. Existing Improvements: Investigate and verify location of existing improvements to which the new work is to be connected.
1. Making necessary adjustment in line and grade to align the new work with the existing improvements must be approved by the ENGINEER prior to any change.
3.2 PREPARATION
A. Forms: Use wood or metal forms, straight and free from warp, clean, and sufficient strength to resist springing during the process of depositing concrete against them.
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1. Use full depth of the concrete forms.
3.3 INSTALLATION
A. Sidewalks, Sidewalk Ramps, Driveways and Driveway Approaches: Construct all sidewalks and sidewalk ramps four (4) inches thick except at driveways and alleys. Construct thickness of the sidewalks six (6) inches at driveways and alleys. Construct sidewalks five (5) feet wide unless otherwise noted on the Plans or directed by the ENGINEER, and slope 1/4-inch per foot towards the center of the road. Normally, sidewalks will be located within the right-of- way, parallel the property lines, at a distance of 1-foot from the property line.
1. Construct alleys, driveways and approaches six (6) inches thick. Construct the width of the driveways and driveway approaches as shown on the Plans or as directed by the ENGINEER.
B. Removal of Existing Curb for Sidewalk Ramps and Driveway Approaches: Conform construction of sidewalk ramps within street intersections where curbed pavement existing to the current FDOT Roadway and Traffic Design Standards.
1. Saw cut, to full depth of pavement, and remove a minimum of an 18-inch wide curb and gutter section where there is no proper curb drop for the sidewalk ramp or driveway approach. When mountable curbs are present, remove a 24- inch wide curb and gutter section for the construction of sidewalk ramps, as specified above.
2. Remove curb and gutter as determined by the ENGINEER in the field but remove curb and gutter at least as wide as the proposed sidewalk ramp plus 1-foot on each side.
3. Replace the removed curb and gutter section with materials, equal to what was removed and seal joint with hot poured rubber asphalt.
C. Install 5/8 inch diameter self tapping hook bolts, in the existing concrete pavement as indicated on the Plans prior to placing concrete for the removed curb and gutter section.
D. Placement of Forms: Use wood forms, straight and free from warp, of nominal depth for sidewalk sections less than 25 feet in length.
1. Stake forms to line and grade in a manner that will prevent deflection and settlement.
2. When unit slab areas are to be poured, place slab division forms such that the slab division joints will be straight and continuous.
3. Set forms for sidewalk ramps to provide a grade toward the centerline of the right-of-way in accordance with current standards. Use a uniform grade, except as may be necessary to eliminate short grade changes.
4. Oil forms before placing concrete. Leave forms in place at least 12 hours after the concrete is placed. Place forms ahead of the pouring operations to maintain uninterrupted placement of concrete.
5. The use of slip form pavers can be allowed when approved by the ENGINEER in lieu of the construction system described above. 5000-79695 02515-3 Florida Governmental Utility Authority Waterway Estates Interconnect 60% Submittal
E. Joints: Construct transverse and longitudinal expansion and plane-of-weakness joints at the locations specified herein, or as indicated on the Plans or as directed by the ENGINEER.
1. Place the transverse expansion joints for the full width and depth of the new work. Use transverse expansion joints placed against an existing pavement a minimum of six (6) inches deep but no less than the thickness of the concrete being placed.
2. Conform longitudinal expansion joints to the requirements as transverse expansion joints.
3. Construct joints true to line with their faces perpendicular to the surface of the sidewalk. Install the top slightly below the finished surface of the sidewalk. Construct transverse joints at right angles to the centerline of the sidewalk and construct longitudinal joints parallel to the centerline or as directed by the ENGINEER.
4. Place transverse expansion joints, 1/2-inch thick, through the sidewalk at uniform intervals of not more than 50 feet and elsewhere as shown on the Plans, or as directed by the ENGINEER.
5. Place expansion joints, 1/2-inch thick, between the sidewalk and back of abutting parallel curb, buildings or other rigid structures, concrete driveways and driveway approaches. When directed by the ENGINEER, place the expansion joint between sidewalks and buildings 1-Ioot from the property line and parallel to it.
6. Form plane-of-weakness joints every five (5) feet. Form joints by use of slab divisions forms extending to the full depth of the concrete or by cutting joints in the concrete, after floating, to a depth equal to 1/4 the thickness on the sidewalk. Construct cut joints not less than 1/8-inch or more than 1/4-inch in width and finish smooth and at right angles to the centerline on the sidewalk.
F. Placing and Finishing Concrete: Place all concrete on a prepared unfrozen, smooth, leveled, rolled and properly compacted base. Place concrete on a moist surface with no visible water present.
1. Deposit the concrete, in a single layer to the depth specified. Spade or vibrate and compact the concrete to fill in all voids along the forms and joints. Strike off the concrete with a strike board until all voids are removed and the surface has the required grade and cross section as indicated on the Plans, or as directed by the ENGINEER.
2. Float the surface of the concrete just enough to produce a smooth surface free from irregularities. Round all edges and joints with an edger having a 1/4-inch radius.
3. Broom the surface of sidewalks, driveways and approaches to slightly roughen the surface.
4. Texture the surface of the sidewalk ramps with a coarse broom transversely to the ramp slope, and coarser roughen than the remainder of the sidewalk. Contract the ramp slope in color (using a brick-red dye or approved equal) from the remainder of the sidewalk. Comply with minimum color contract and slope requirements from FAC, UFAS, ADAAG, Local Government Standards, or as directed by the ENGINEER.
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G. Curing: After finishing operations have been completed and immediately after the free water has left the surface, completely coat and seal the surface of the concrete (and sides if slip- forming is used) with a uniform layer of white membrane curing compound. Do not thin the curing compound. Apply the curing compound at the rate of one gallon per 200 square feet of surface.
H. Barricades: Place suitable barricades and lights around all newly poured sidewalks, sidewalk ramps, driveways, driveway approaches and curb and gutter sections in order to protect the new work from damage from pedestrians, vehicles and others until the concrete has hardened.
1. Leave barricades in place for a minimum of two (2) days, except for driveway approaches and curb and gutter sections. Leave barricades in place for a minimum of three (3) days.
2. Remove and replace any concrete that suffers surface or structural damage at no additional cost.
I. Protection:
1. Against Rain: Protect new concrete from the effects of rain before the concrete has sufficiently hardened. Have available on the job site at all times enough burlap or 6-mil thick polyurethane film to cover and protect one day's work. Stop work and cover completed work when rain appears eminent. As soon as the rain ceases, uncover the concrete and burlap drag the surface where necessary. Apply curing compound to any areas where the compound has been disturbed or washed away.
2. Against Cold Weather: If concrete is placed between December 15 and February 15, have available on the site sufficient amount of clean, dry straw or hay to cover one (1) day's production. If the temperature reaches 40 degrees F and is falling, place the hay or straw 12 inches thick, immediately after the curing compound is applied.
3. Concrete Temperature Limitations: Do not place concrete when the temperature of the concrete at the point of placement is above 90 degrees F. J. Cleanup: After the concrete has gained sufficient strength, but no sooner than within 12 hours, remove the fixed forms and backfill the spaces on both sides with sound earth of topsoil quality. Compact, level and leave backfill in a neat condition.
K. Gutters and Curbs: Construct gutters and curbs in accordance with Section 520 FDOT Standard Specifications for Road and Bridge Construction, latest edition, including supplements.
3.4 FIELD QUALITY CONTROL
A. Concrete Delivery Ticket: Use a ticket system for recording the transportation of concrete from the batching plant to point of delivery. Issue this ticket to the truck operator at the point of loading and give to the ENGINEER upon delivery.
B. Concrete Delivery Rejection: Remove concrete not permitted for inclusion in the work by the ENGINEER from the site. Rejection of concrete will be determined through Field Quality Control and elapsed time from mixer charging to delivery.
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C. Concrete Testing at Placement: Perform tests of each batch of concrete delivered, each 50 cubic yards, or whenever consistency appears to vary. The sampling and testing of slump, air content and strength will be performed at no cost to the CITY.
1. Sampling: Secure composite samples in accordance with the Method of Sampling Fresh Concrete, ASTM C172. 2. Slump Test: Test in accordance with ASTM C143. Use the least slump possible consistent with workability for proper placing of the various classifications of concrete.
a. Place structural concrete for walls and slabs, by means of vibratory equipment, with a slump of four (4) inches.
b. A tolerance of up to i-inch above the indicated maximum will be allowed for individual batches provided the average for all batches or the most recent ten (10) batches tested, whichever is fewer, does not exceed the maximum limit.
2. Air Content: Determine air content of normal weight concrete in accordance with Method of Test for Air Content of Freshly Mixed Concrete by the Pressure Method, ASTM C23 1, or by the volumetric method, ASTM C 173, for each strength test.
3. Compressive Strength: Make two (2) strength tests of three (3) samples each for each 50 cubic yards, or fraction thereof, of each mix design of concrete placed in anyone (1) day.
a. Handling Samples: Mold and cure three (3) specimens from each sample in accordance with Method of Making and Curing Concrete Test Specimens in the Field, ASTM C31. Record any deviations from the requirements of this Standard in the test report.
b. Testing: Test specimens in accordance with Method of Test for Compressive Strength of Cylindrical Concrete Specimens, ASTM C39. Test one (1) specimen at seven (7) days for information and test two (2) at 28 days for acceptance. Use the average of the strengths of the two (2) specimens tested at 28 days. Discard results if one (1) specimen in a test manifests evidence of improper sampling, molding or testing, and use the strength of the remaining cylinder. Should both specimens in test shown any of the above defects, discard the entire test.
c. Acceptance of Concrete: The strength level of the concrete will be considered satisfactory so long as the averages of all sets of three consecutive strength test results equal or exceed the specified 28-day strength and no individual strength test results falls below the specified 28-day strength by more than 500 psi. If the strength test is not acceptable, perform further testing to qualify the concrete.
d. Concrete Temperature: Determine the temperature of concrete sample for each strength test.
D. Reductions due to deficiencies in thickness or compressive strength are additive, that is, if an area is deficient by 3/8 inch and under strength by 200 psi, the total reduction is 20% plus 02% or 40% reduction.
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END OF SECTION
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SECTION 02576
PAVEMENT REPAIR AND RESTORATION
PART 1 GENERAL
1.1 SCOPE OF WORK
A. Furnish all labor, materials, equipment, and incidentals required and remove and replace pavements over trenches excavated for installation of pipelines as shown on the drawings and/or specified herein.
1.2 GENERAL
A. All damage, as a result of work under this project, done to existing pavement, driveways, paved areas, curbs and gutters, sidewalks, shrubbery, grass, trees, utility poles, utility pipe lines, conduits, drains, catch basins, or stabilized areas or driveways and including all obstructions not specifically named herein, shall be repaired in a manner satisfactory to the ENGINEER. Bid prices shall include the furnishing of all labor, materials, equipment, and incidentals necessary for the cutting, repair, and restoration of the damaged areas unless pay items for specific types of repair are included in the Bid Form.
B. Keep the surface of the backfilled area of excavation in a safe condition and level with the remaining pavement until the pavement is restored in the manner specified herein. All surface irregularities that are dangerous or obstructive to traffic are to be removed. The repair shall conform to applicable OWNER or State requirements for pavement repair and as described herein.
C. All materials and workmanship shall be first class and nothing herein shall be construed as to relieve the CONTRACTOR from this responsibility. The OWNER reserves the right to require soil bearing or loading tests or materials tests, should the adequacy of the foundation or the quality of materials used be questionable. Costs of these tests shall be borne by the OWNER, if found acceptable; the costs of all failed tests shall be borne by the CONTRACTOR.
D. All street and road repair shall be made in accordance with the details indicated on the drawings and in accordance with the applicable requirements of these Specifications and meeting the permit requirements and approval of the governing Department of Transportation agencies.
E. Pavement or roadway surfaces cut or damaged shall be replaced by the CONTRACTOR in equal or better condition than the original, including stabilization, base course, surface course, curb and gutter or other appurtenances. The CONTRACTOR shall obtain the necessary permits prior to any roadway work. Additionally, the CONTRACTOR shall provide advance notice to the appropriate authority, as required, prior to construction operations.
1. Roadway Restoration (within Lee County Department of Transportation & Engineering jurisdiction): Restoration shall be in accordance with the requirements set forth in the "Right- of-Way Utility Construction Activities Policy" and these Standards. The materials of construction and method of installation, along with the proposed restoration design for items not referred or specified herein, shall receive prior approval from Lee County DOT.
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a. Where existing pavement is to be removed, the surface shall be mechanical saw cut prior to trench excavation, leaving a uniform and straight edge parallel or perpendicular to the roadway centerline with minimum disturbance to the remaining adjacent surfacing. The width of cut for this phase of existing pavement removal shall be minimal.
b. Immediately following the specified backfilling and compaction, a temporary sand seal coat surface shall be applied to the cut areas. This temporary surfacing shall provide a smooth traffic surface with the existing roadway and shall be maintained until final restoration. Said surfacing shall remain for a minimum of ten (10) days in order to assure the stability of the backfill under normal traffic conditions. Thirty (30) days following this period and prior to sixty (60) days after application, the temporary surfacing shall be removed and final roadway surface restoration accomplished.
c. In advance of final restoration, the temporary surfacing shall be removed and the existing pavement mechanically sawed straight and clean to the stipulated dimensions, if needed. Following the above operation, the CONTRACTOR shall proceed immediately with final pavement restoration in accordance with the requirements set forth by Lee County Department of Transportation.
2. Roadway Restoration (outside Lee County Department of Transportation jurisdiction) - Work within the rights-of-way of public thoroughfares which are not under jurisdiction of Lee County, shall conform to the requirements of the Governmental agency having jurisdiction or the Florida Department of Transportation, if no governmental agencies have jurisdiction. Work within State Highway right-of-way shall be in full compliance with all requirements of the permit drawings, and to the satisfaction of the Florida Department of Transportation.
1.3 QUALITY ASSURANCE
A. Applicable provisions of the latest version of the Florida Department of Transportation "Standard Specifications for Road and Bridge Construction", and Supplemental Specifications hereunder govern the work under this Section. The Florida Department of Transportation will hereafter be referred to as FDOT.
PART 2 PRODUCTS
2.1 MATERIALS
A. All materials utilized in flexible base pavement and base course shall be as specified in the latest version of the Florida Department of Transportation "Standard Specifications for Road and Bridge Construction".
PART 3 EXECUTION
3.1 CUTTING PAVEMENT
A. Cut and remove pavement as necessary for installing the new pipelines and appurtenances and for making connections to existing pipelines.
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B. Before removing pavement, the pavement shall be marked for cuts nearly paralleling pipelines and existing street lines. Asphalt pavement shall be cut along the markings with a jackhammer, rotary saw, or other suitable tool, leaving a uniform and straight edge with minimum disturbance to the remaining adjacent surface.
C. No pavement shall be machine pulled until completely broken and separated along the marked cuts.
D. The pavement adjacent to pipeline trenches shall neither be disturbed nor damaged. If the adjacent pavement is disturbed or damaged, irrespective of cause, remove the damaged pavement and shall replace it at his own expense.
3.2 GENERAL RESTORATION
A. The restoration of existing street paving, driveways, etc., shall be restored, replaced or rebuilt using the same type of construction as was in the original. Be responsible for restoring all such work, including sub-grade and base courses where present. Obtain and pay for such local or other governmental permits as may be necessary for the opening of streets. Meet any requirements other than those herein set forth which may effect the type, quality and manner of carrying on the restoration of surfaces by reason of jurisdiction of such governmental bodies.
B. In all cases, maintain, without additional compensation, all permanent replacement of street paving, done by him under this Contract until accepted by the OWNER, including the removal and replacement of such work wherever surface depressions or underlying cavities result from settlement of trench backfill.
C. Complete all the final resurfacing or re-paving of streets or roads, over the excavations and relay paving surfaces of roadbed that have failed or been damaged prior to acceptance by the OWNER. Backfilling of trenches and the preparation of sub-grades shall conform to the requirements of Section 02221.
D. All re-paving or resurfacing shall be done in accordance with Florida Department of Transportation Specifications, to which the following requirement of trench backfill will be added: Where pipeline construction crossed paved areas such as streets, the top 24 inches of trench below the road bases or concrete slabs shall be backfilled with compacted A-4 or better matter that will provide a bearing value of not less than 75 when tested by the Florida Department of Transportation Soil Bearing Test Methods.
3.3 PRIME AND TACK COATS
A. The work shall consist of the application of bituminous prime and tack coats on the previously prepared base course in accordance with Section 300 of the FOOT Specifications.
3.4 WEARING COURSE
A. The work shall consist of the construction of plant-mixed hot bituminous pavement to the thickness indicated in the drawings conforming to Type III asphaltic concrete in accordance with Section 333 of the FOOT Specifications. The requirements for plant and equipment are specified in Section 320 and the general construction requirements for asphaltic concrete pavement are contained in Section 330 of the FOOT specifications.
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3.5 TESTING
A. All field testing shall be performed by an independent laboratory employed by the OWNER. All materials shall be tested and certified by the producer. Tests repeated because sub-grade or base does not meet specified compaction shall be at the CONTRACTOR's expense.
3.6 MISCELLANEOUS RESTORATION
A. Sidewalks cut or damaged by construction shall be restored in full sections or blocks to a minimum thickness of four inches. Concrete curb or curb gutter shall be restored to the existing height and cross section in full sections or lengths between joints. Concrete shall be as specified on the drawings. Grassed yards, shoulders and parkways shall be restored to match the existing sections with grass seed or sod of a type matching the existing grass.
3.7 CLEANUP
A. After all repair and restoration or paving has been completed, all excess asphalt, dirt, and other debris shall be removed from the roadways. All existing storm sewers and inlets shall be checked and cleaned of any construction debris.
END OF SECTION
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SECTION 02607
SEWER MANHOLES
PART 1 GENERAL
1.1 SUMMARY
A. Section Includes: Requirements for providing sewer manholes and all other appurtenances for a complete installation. Provide manholes built without steps and in accordance with the standard details shown in Section 9 of the Lee County Utilities Operations Manual. Except as otherwise specified, construct sewer manholes of precast reinforced concrete sections conforming to ASTM C 478.
B. Related Work Specified in Other Sections Include:
1. Section 02604 -HOPE Concrete Protective Liner 2. Section 02605 -Fiberglass Reinforced Plastic (FRP) Concrete Protective Liner 3. Section 02606 -lET Coating System 4. Section 05540 -Metal Casings
1.2 REFERENCE
A. Codes and standards referred to in this Section are:
1. ASTM C 76 - Specification for Reinforced Concrete Culvert, Storm Drain and Sewer Pipe.
2. ASTM C 478 Specification for Precast Reinforced Concrete Manhole Sections
3. ASTM C 32 Specification for Sewer and Manhole Brick (Made for Clay or Shale)
4. ASTM C 443 Specification for Joints for Circular Concrete Sewer and Culvert Pipe, Using Rubber Gaskets [Metric)
1.3 SUBMITTALS
A. Shop Drawings: Submit shop drawings of sewer manholes as specified in Division 1.
B. Quality Control: Submit shop and fie ld test reports of concrete samples tested in an approved laboratory.
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1.4 DELIVERY, STORAGE AND HANDLING
A. General: Take every precaution to prevent injury to the manhole sections during transportation and unloading. Unload manhole sections using skids, pipe hooks, rope slings, or suitable power equipment, if necessary, and keep the sections under control at all times. Do not allow the manhole sections to be dropped, dumped or dragged under any conditions. Follow applicable requirements specified in Division 1.
B. Damaged Section: If any manhole section is damaged in the process of transportation or handling, reject and immediately remove such sections from the site, and replace the damaged manhole sections at no increase in Contract Amount.
PART 2 PRODUCTS
2.1 MANUFACTURERS
A. Acceptable manufacturers are listed below. Other manufacturers of equivalent products may be submitted.
1. Preformed Joint Sealing Compound:
a. Ram-Nek, as manufactured by K.T. Snyder Company, Inc., Houston, TX
2. Frame and covers as manufactured by U. S. Foundry, Model 240-8
2.2 MATERIALS
A. Concrete, Steel Reinforcement and Aggregates: Provide reinforced concrete, cementitious materials, aggregates and steel reinforcement conforming to the requirements of ASTM C 478, with Grade 40 reinforcement bars, Type II cement, and a minimum wall thickness of 8 inches.
B. Manhole Frames and Covers: Provide manhole frames and covers as shown on the Lee County Standard details. Castings for manhole frames, covers and other items shall conform to the ASTM Designation A48, Class 30. Castings shall be true to pattern in form and dimensions and free of pouring faults and other defects in positions which would impair their strength, or otherwise make them unfit for the service intended. The scating surfaces between frames and covers shall be machined to fit true so the frames and covers do not shift under traffic conditions or permit entry of storm water from flooding. Lifting or "pick" holes shall be provided, but shall not penetrate the cover. The words SANITARY SEWER, as well as LEE COUNTY shall be cast in all manhole covers. All manhole frames and covers shall be traffic bearing unless otherwise specified. Frames and covers shall be fully bedded in mortar in the correct finish grade elevation with adjustment brick courses or concrete grade rings installed in conformance with the Lee County Utilities Operation Manual.
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C. Preformed Joint Sealing Compound : Provide preformed joint sealing compound for joining manhole sections.
D. Concrete Protective Liner: Provide concrete protective liner conforming to Sections 02604, 02605 or 02606.
E. Pipeline Connections: Provide neoprene boots with type 316 stainless steel clamps of a design approved by Lee County Utilities for joining sewers to manhole riser sections. The unfilled portion of the connection shall be filled with Ram-Nek.
F. Inflow Protectors: All manholes under non-traffic bearing areas shall have a plastic inflow protector installed. All manholes under traffic bearing areas shall have an inflow protector installed manufactured from a high-quality 304 stainless steel with a consistent thickness of not less than 18 gage. The inflow shall have a deep dish bowl design with no less than 8 inches in depth to allow easy and unobstructed removal of the manhole cover. The manhole inflow protector is to be manufactured with a one-piece rubber gasket installed at the factory for a tight, consistent fit. The rubber gasket is to be designed to securely wrap around the entire leading edge of the inflow protector at the point where it comes in contact with the manhole frame and cover. The wrap around rubber gasket is to be manufactured to a width of no less than 3/8 inches, consistent on top and bottom of the leading edge of the inflow protector. The gasket shall be no more than 3/32 inches thick. The insert removal handle shall be manufactured of a high-quality stainless steel for strength and durability. The handle is installed in such a way that it does not interfere with the installation or removal of the manhole lid. The insert handle will be manufactured to withstand a minimum pull force of 500 pounds before it fails or separates from the insert. The inscription "PROPERTY OF LEE COUNTY UTILITIES" shall be etched, at the base of the handle frame, to provide a long-lasting identification marker for the owner. The inflow protector shall be as manufactured by Sewer Shield, Inc., Maitland, FL, or an approved equal.
G. Master Manholes: Master manholes shall have a double cover with an outer 35inch opening and a smaller inner 22-1 /4-inch access cover and shall be constructed in accordance with the Lee County Standard Details. The double manhole rings and covers shall be as manufactured by U.S. Foundry Model 672AF-M-ORS or an approved equal. The connecting gravity sewer between the master manhole and the wet well shall be PVC C9DD or C9D5 SDR 18 pipe material. For manholes receiving flows from 16-inch or larger pipe, a six-feet diameter master manhole will be required.
2.3 SOURCE QUALITY CONTROL
A. At least three cylinders will be taken each day that manhole sections are cast, with batch samples to be designated by the laboratory representative. At least one set of cylinders will be taken from each 9 cubic yards of concrete used in manhole section construction. These samples will be tested for strength. If the samples fail to meet specified minimum concrete strength requirements, all manhole sections manufactured from the concrete from which the cylinders were made will be rejected.
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B. The OWNER reserves the right to core manholes either at the job site or point of delivery to validate strength of concrete and placement of steel. If cores fail to demonstrate the required strength or indicate incorrect placement of reinforcing steel, all sections not previously tested will be considered rejected until sufficient additional cores are tested, at no increase in Contract Amount, to substantiate conformance to these requirements.
PART 3 EXECUTION
A. Lifting Holes: Lifting holes through the structure shall be grouted with non-shrink grout.
B. Precast Base: The design of the structure shall include a precast base of not less than 8 inches in thickness poured monolithically with the bottom section of the manhole walls.
C. Joining Manhole Sections: Precast sections shall be joined using Ram-Nek plastic joint sealing compound and trimmed prior to grouting. Non-shrink grout shall be used inside and outside for sealing between manhole precast sections and shall be of a type acceptable to Lee County Utilities and designed for use in water. All openings and joints shall be sealed watertight.
D. Top Termination: Manhole tops shall terminate at such elevations as will permit laying up grade rings under the manhole frame to make allowances for future street grade adjustments.
E. Drop Connections: Drop connections, where required on precast manholes, shall be manufactured with the manhole elements at the casting yard. Drop manholes shall be constructed per the Lee County Standard Details.
F. Internal Protection: Unless otherwise approved by Lee County Utilities, all manholes shall be protected internally from deterioration by either of the following:
1 GU manhole liner, as manufactured by GU Industries, Inc. or
2 AGRU, Suregrip high-density polyethylene (HOPE) polypropylene (PP- R)protective liner system, or
3 lET Coating system -surface preparation shall include pressure washing at 5,000 psi, abrasive blasting with black beauty steel slag and application of the lET coat at three (3) different intervals to a total thickness of 125 mils.
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The liner or coating system must be installed per manufacturer's recommendation and completely protect the structure from corrosion. The liner or coating system must extend and seal onto manhole ring, seal onto and around pipe openings, and any other protrusions, completely cover the bench and flow invert. Provide a five (5)-year unlimited warranty on all workmanship and products. The work which includes the surface preparation and application of the coating or liner system, shall protect the structure for at least five (5) years from all leaks and from failure due to corrosion from exposure to corrosive gases such as hydrogen sulfide.
G. Coal Tar Epoxy: All manhole, wet well, and valve vault exteriors shall be coated with two (2) coats of coal tar epoxy to a minimum thickness of 18 mils. Where no corrosive conditions are expected in a wet well or manhole, with Lee County Utilities specific written approval, the interior of the manhole may be coated with two (2) coats coal tar epoxy to a minimum thickness of 18 mils.
END OF SECTION
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SECTION 02616
DUCTILE IRON PIPE AND FITTINGS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required, install, disinfect and test ductile iron pipe and fittings as shown on the Drawings and as specified herein.
B. Piping shall be located substantially as shown on the Drawings. The ENGINEER reserves the right to make such modifications in locations as may be found desirable to avoid interference between pipes or for other reasons. Pipe fitting notation is for the CONTRACTOR’S convenience and does not relieve him/her from installing and jointing different or additional items where required to achieve a complete piping system.
C. Where the word "pipe" is used it shall refer to pipe, fittings, or appurtenances unless otherwise noted.
1.02 RELATED WORK
A. Delivery, Storage and Handling is included in Section 01600.
B. Trenching, Backfilling and Compaction is included in Section 02221.
C. Granular Fill Material is included in Section 02230.
D. Sedimentation and Erosion Control is included in Section 01110.
E. Pavement Repair and Resurfacing is included in Section 02576.
F. Valves, Hydrants and Appurtenances are included in Section 02640.
1.03 SUBMITTALS
A. Submit, to the ENGINEER, within 30 days of Effective Date of the Agreement, the name of the pipe and fitting suppliers and a list of materials to be furnished.
B. Submit, in accordance with Section 01300, shop drawings and product data for the ENGINEER’S review.
C. Submit copies of design calculations in accordance with Paragraph 2.02 below.
D. Submit anticipated production and delivery schedule.
E. Prior to shipment of pipe, submit a certified affidavit of compliance from the manufacturer stating that the pipe, fittings, gaskets, linings and exterior coatings for this project have been manufactured and tested in accordance with AWWA and ASTM standards and requirements specified herein.
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1.04 REFERENCE STANDARDS
A. American Society for Testing and Materials (ASTM)
1. ASTM A193 – Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service.
2. ASTM A194 – Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High- Pressure and High-Temperature Service.
3. ASTM A716 – Standard Specification for Ductile Iron Culvert Pipe.
4. ASTM A307 – Standard Specification for Carbon Steel Bolts and Studs 60.000 PSI Tensile Strength.
5. ASTM C150 - Standard Specification for Portland Cement.
B. American Water Works Association (AWWA)
1. AWWA C104 – Cement-Mortar Lining for Ductile-Iron Pipe and Fittings for Water.
2. AWWA C105 – Polyethylene Encasement for Ductile-Iron Pipe Systems.
3. AWWA C110 – Ductile-Iron and Gray-Iron Fittings, 3-in through 48-in (75mm Through 1219mm) for Water.
4. AWWA C111 – Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings.
5. AWWA C150 – Thickness Design of Ductile-Iron Pipe.
6. AWWA C151 – Ductile-Iron Pipe, Centrifugally Cast, for Water.
7. AWWA C153 – Ductile- Iron Compact Fittings, 3-in through 24-in and 54-in through 64-in, for Water.
8. AWWA C550 – Protective Interior Coatings for Valves and Hydrants
9. AWWA C600 – Installation of Ductile-Iron Water Mains and Their Appurtenances.
10. AWWA C606 – Grooved and Shouldered Joints
11. AWWA C651 - Disinfecting Water Mains.
C. National Sanitation Foundation (NSF)
1. ANSF B61.1 – Drinking Water System Components Health Effects
D. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.
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1.05 QUALITY ASSURANCE
A. Each length of ductile iron pipe supplied for the project shall be hydrostatically tested at the point of manufacture to 500 psi for a duration of 10 seconds per AWWA C151. Testing may be performed prior to machining bell and spigot. Failure of ductile iron pipe shall be defined as any rupture of the pipe wall. Certified test results shall be furnished in duplicate to the ENGINEER prior to time of shipment.
B. Inspection of the pipe and fittings will also be made by the ENGINEER or representative of the Owner after delivery. The pipe shall be subject to rejection at any time on account of failure to meet any of the requirements specified herein, even though sample pipes may have been accepted as satisfactory at the place of manufacture. Pipe rejected after delivery shall be marked for identification and shall be removed from the job.
C. All pipe and fittings shall be permanently marked with the following information:
1. Manufacturer, date.
2. Size, type, class, or wall thickness.
3. Standard produced to (AWWA, ASTM, etc).
1.06 DELIVERY, STORAGE AND HANDLING
A. Care shall be taken in loading, transporting, and unloading to prevent injury to the pipe. Under no circumstances shall the pipe be dropped or skidded against each other. Slings, hooks, or pipe tongs shall be used in pipe handling.
B. Materials, if stored, shall be kept safe from damage. The interior of all pipes, fittings and other appurtenances shall be kept free from dirt or foreign matter at all times.
C. Pipe shall not be stacked higher than the limits recommended by its manufacturer. The bottom tier shall be kept off the ground on timbers, rails, or concrete. Stacking shall conform to manufacturer's recommendations.
D. Gaskets for mechanical and push-on joints to be stored shall be placed in a cool location out of direct sunlight. Gaskets shall not come in contact with petroleum products. Gaskets shall be used on a first-in, first-out basis.
PART 2 PRODUCTS
2.01 MATERIALS
A. General
1. If not specified otherwise, provide flanged joints for exposed pipings, and mechanical or push- on joints for buried piping.
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B. Ductile Iron Pipe and Fittings
1. Flanged Pipe – Fabricated in accordance with requirements of AWWA C115, Thickness Class 53.
2. Non-Flanged Pipe – Conform to AWWA C150/C151 for material, pressure, thickness, dimensions, tolerances tests, markings, and other requirements. The pipe shall be supplied in standard lengths as much as possible. Thickness design shall be a minimum Class 350 for diameters up to 20-inches and minimum Class 250 for piping diameters 24-inches and larger.
3. Ductile iron pipe shall be manufactured by U.S. Pipe and Foundry Company, Inc.; American Cast Iron Pipe Company; McWane Cast Iron Pipe Co., Griffin Pipe Co., or equal.
C. Joints
1. Ductile iron pipe/fitting joints shall be push-on rubber gasket type or rubber-gasket mechanical joint per AWWA C111 in unrestrained areas, except where flanged joints are required as shown on the drawings. In restrained areas, both pipe and fitting joints shall be push on rubber gasket, locking ring type restrained joints per the manufacturer' standard described in Paragraph 3. All gasket materials shall comply with Table 5-1 of AWWA M-41. Rubber- gasket joints shall conform to AWWA C111. Gasket shall be of styrene butadiene rubber (SBR).
2. Flanged joints shall be 125 pound threaded flanges conforming to ANSI B16.1 for pipe and AWWA C153 for fittings. The pipe flanges shall be flat faced and suitable for 250 psi working pressure. Gaskets shall be ethylene propylene (EPDM), 1/8-in thick, full face and meeting the material requirements of AWWA C115. Flanged joints shall be made up with 316 stainless steel bolts, nuts and washers. Stainless steel bolts, nuts and washers shall not be painted.
3. Restrained joints shall be restrained push-on joints, TR Flex by U.S. Pipe and Foundry; Lok- Ring by American Cast Iron Pipe Company, "Snap Lok" by Griffin Pipe Products Company, "Superlok" by Clow Water Systems Company or approved equal. Joints shall be suitable for 250 psi working pressure and be fabricated of heavy section ductile iron casting. Bolts and nuts shall be low carbon steel conforming to ASTM A307, Grade B.
a. The minimum number of restrained joints required for resisting forces at fittings and changes in direction of the pipe shall be determined from the length of restrained pipe on each side of the fittings and changes in direction necessary to develop adequate resisting friction with the soil, The required lengths of restrained joints shall be as shown on the Drawings.
b. Restrained pipe joints that achieve restraint by incorporating cut out sections in the wall of the pipe shall have a minimum wall thickness at the point of the cut out that corresponds with the minimum specified wall thickness for the rest of the pipe.
c. For up through 48-inch diameter ductile iron pipe only, the following may be used as an alternative restraint system
i. The optional mechanical joint restraint shall be incorporated in the design of a follower gland. The gland shall be manufactured of ductile iron conforming to
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ASTM A536. Dimensions of the gland shall be such that it can be used with the standard mechanical joint bell and tee-headed bolts, as specified with the pipe.
ii. The restraint mechanism shall consist of numerous individually activated gripping surfaces to maximize restraint capability. The gripping surfaces shall be wedges designed to spread the bearing surfaces on the pipe. Actuation of the gripping wedges shall be by torque limiting twist-off nuts sized same as T bolts for mechanical joints. When the nut is sheared off, standard hex nut shall remain.
iii. The restraint device for ductile iron pipe shall have a working pressure of at least 250 psi and a safety factor of 2:1.
iv. Pipe manufacturer proprietary mechanical joint restraint systems that utilize a wedge style gripping systems or a gland/ring positive restraint system will be considered acceptable on a case by case basis as determined by the Engineer.
v. The restraint device shall be EBAA Iron Megalug Series 1100, or approved equal.
4. All fittings for lines 6-in diameter and larger shall have restrained joints.
D. Fittings
1. Pipe fittings shall be ductile iron with pressure rating of 350 psi for 20-in and smaller piping and 250 psi for 24-in and larger piping. Fittings shall meet the requirements of AWWA C153. Fittings shall have the same pressure rating, as a minimum, of the connecting pipe.
2. Closures shall be made with mechanical joint ductile iron solid sleeves and shall be located in straight runs of pipe at minimum cover outside the limits of restrained joint sections. Location of closures shall be subject to approval of the ENGINEER.
E. Coating/Lining
1. All pipe and fittings shall have a bituminous outside coating in accordance with AWWA C151 and C110, respectively. The interior of all pipe and fittings shall be epoxy coated with a dry film thickness of 40 mils minimum. Epoxy coating shall be Protecto 401, or approved equal.
2.02 DUCTILE IRON PIPE DESIGN
A. Ductile iron pipe shall have a minimum tensile strength of 60,000 psi with a minimum yield strength of 42,000 psi. Design shall be done for external and internal pressures separately using the larger of the two for the net design thickness. Additional allowances shall be made for service allowance and casting tolerance per AWWA C150. The pipe classes determined for various sizes and conditions shall provide the total calculated thickness at a minimum or conform to minimum pipe class specified above, whichever is greater.
B. Design for the net thickness for external loading shall be taken as the greater of the following conditions:
1. 3-ft of cover with AASHTO H-20 wheel loads, with an impact factor of 1.5.
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2. Depth from existing ground level of future proposed grade (whichever is greater) to top of pipe as shown on the Drawings, with truck load.
3. Soil Density: 125 lbs/cu ft
4. Laying Conditions; AWWA C150, Type 2.
C. Design for the net thickness shall be based upon the following internal pressure conditions:
1. Design pressure: 150 psi
2. Surge allowance: 100 psi
3. Safety factor: 2
4. Total internal pressure design: 2 (150 + 100) = 500 psi
5. E’: 300 psi
D. Copies of design calculations showing that the pipe meets all requirements specified herein shall be furnished to the ENGINEER for approval during shop drawing review in accordance with Section 01300. A yield strength of 42,000 psi shall be used during design calculations.
PART 3 EXECUTION
3.01 GENERAL
A. Care shall be taken in loading, transporting and unloading to prevent injury to the pipe or coatings. Pipe and fittings shall not be dropped. All pipe and fittings shall be examined before laying and no piece shall be installed which is found to be defective. Damage to the pipe coatings shall be repaired per manufacturer's recommendations.
B. If any defective pipe is discovered after it has been laid, it shall be removed and replaced with a sound pipe in a satisfactory manner. All pipe and fittings shall be thoroughly cleaned before laying, shall be kept clean until they are used in the work and when installed or laid, shall conform to the lines and grades required.
3.02 INSTALLING DUCTILE IRON PIPE AND FITTINGS
A. Ductile iron pipe and fittings shall be installed in accordance with requirements of AWWA C600, except as otherwise specified herein. A firm, even bearing throughout the length of the pipe shall be provided by digging bell holes at each joint and by tamping backfill materials at the side of the pipe to the springline per details shown on the Drawings. Blocking will not be permitted.
B. All pipe shall be sound and clean before laying. When laying is not in progress, open ends of the pipe shall be closed by a watertight plug or other approved means. Sufficient backfill shall be placed to prevent flotation. The deflection at joints shall not exceed 75 percent of allowable deflection recommended by manufacturer.
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C. All ductile iron pipe laid underground shall have a minimum of 3-ft of cover unless otherwise shown on the Drawings or as specified herein. Pipe shall be laid such that the invert elevations shown on the Drawings are not exceeded.
D. Fittings, in addition to those shown on the Drawings shall be provided, where required, in crossing utilities which may be encountered upon opening the trench. Solid sleeve closures shall be installed at locations approved by the ENGINEER.
E. The pipe interior shall be maintained dry and broom clean throughout the construction period.
F. When cutting pipe is required, the cutting shall be done by machine, (abradive wheel saw) leaving a smooth cut at right angles to the axis of the pipe. Cut ends of pipe to be used with a bell shall be beveled to conform to the manufactured spigot end. Cement lining shall be undamaged. Cutting of restrained joint pipe will not be allowed, unless approved at specific joints in conjunction with the use of restrainer glands by EBAA Iron or field adaptable restrained joints.
G. Jointing Ductile-Iron Pipe
1. Push-on joints shall be made in strict accordance with manufacturer's instructions and AWWA C600. Pipe shall be laid with bell ends looking ahead. A rubber gasket shall be inserted in the groove of the bell end of the pipe. The joint surfaces shall be cleaned and lubricated and the plain end of the pipe shall be aligned with the bell of the pipe to which it is to be joined and pushed home.
2. Mechanical joints shall be assembled in strict accordance with the manufacturer's instructions and AWWA C600. Pipe shall be laid with bell ends looking ahead. To assemble the joints in the field, thoroughly clean and lubricate the joint surfaces and rubber gasket. Bolts shall be tightened to the specified torques. Under no condition shall extension wrenches or pipe over handle of ordinary ratchet wrench be used to secure greater leverage.
3. Flanged joints shall be installed where shown on the Drawings. Extreme care shall be exercised to insure that there is not restraint on opposite ends of pipe or fitting which will prevent uniform gasket compression, cause unnecessary stress, bending or torsional strains to flanges or flanged fittings. Adjoining push-on joints shall not be assembled until flanged joints have been tightened. Bolts shall be tightened alternately and evenly. After installation apply a bitumastic coating to bolts and nuts.
4. Restrained joints shall be installed according to pipe manufacturer's instructions.
H. All blow-offs, outlets, valves, fittings, and other appurtenances required shall be set and jointed as indicated on the Drawings in accordance with the manufacturer's instructions.
I. The flexible joint pipe shall be installed in accordance with the manufacturer’s recommendations. In addition, the installed deflection shall be limited to 12 degrees per joint and provisions shall be made where required to prevent flotation or buoyancy of the pipe.
J. Couplings shall be installed where shown. Couplings shall not be assembled until adjoining push-on joints have been assembled. After installation, apply a heavy bitumastic coating to bolts and nuts.
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3.03 POLYETHYLENE ENCASEMENT
A. Where necessary, the polyethylene encasement shall be installed in accordance with either method specified in AWWA C105 and the manufacturer’s instructions. All ends shall be securely closed with tape and all damaged areas shall be completely repaired to the satisfaction of the Engineer. Installation shall be at locations shown on the Drawings.
3.04 CLEANING
A. The Contractor shall protect the pipes from debris and animals before, during and after the installation. At the end of the day or when the construction is stopped for any reason, the pipeline shall be capped to prevent entrance of any dirt, stones, pieces of wood, animals and/or other materials.
B. Because of the size of the finished water main, the Contractor shall expect that the cleaning may be done when a certain amount of pipe is installed and ready for pressure/leakage testing. The minimum length requirement will be decided by the Contractor and Engineer during the preconstruction meeting. A section of main will be considered ready for testing after completion of all thrust restraint and backfilling. The Contractor shall submit the cleaning procedure for Engineer’s review at least 10 days before starting the cleaning of the first section.
C. When a section of pipe is ready for pressure/leakage test, thoroughly clean the entire pipe by flushing with water or other means to remove all dirt, stones, pieces of wood, or other material which may have entered during the construction period. All debris shall be removed from the pipeline. The lowest segment outlet shall be flushed last to assure debris removal. Lowndes County Standard Specifications for Water Mains and Accessories (Section 02665) states that the water flow velocity shall be greater than 2.5 feet per second to adequately remove debris from pipe and valve seats. The Contractor shall partially operate valves and hydrants to clean out seats.
D. Temporary blow-offs shall be installed for the purpose of clearing the water main. Blow-offs installed on water mains up to and including 12 inches shall be the same diameter as the water main. Pipes shall be flushed at blow off points and at dead ends to achieve a minimum flow velocity specified in Paragraph C above, and a minimum of 3 turnovers of treated water shall be used in the flushing operation. Blow-offs installed on 16 inch water mains and larger shall be the next smaller size, in diameter, than the water main being tested. Temporary blow-offs shall be removed and plugged after the main is cleared.
E. After the pipe lines are cleaned and if the ground-water level is above the pipe, or following a heavy rain, the Engineer will examine the pipe for leaks. If defective pipes or joints are discovered at this time, they shall be repaired or replaced by the Contractor.
F. The Contractor shall be responsible for the proper disposal or discharge of the water during the flushing operation. The Contractor shall be responsible for repairing all damages due to the flushing operation at no cost to the Owner.
3.05 TESTING
A. After installation, the pipe shall be tested for compliance as specified herein. Furnish all necessary equipment and labor for the pressure test and leakage test on the pipelines. Each segment of water main between main valves shall be tested individually.
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B. Submit detailed test procedures and method for Engineer’s approval at least 10 days before starting the test. Testing shall be conducted in accordance with AWWA C600.
C. Pressure pipelines shall be subjected to a hydrostatic pressure of 50 percent above the normal operating pressure (or 150 psi whichever is greater). This test pressure shall be maintained for a minimum of 2 hours. The leakage rate shall not exceed those indicated in Section 01445, Pipeline Testing, and shall comply with the requirements of the City of Valdosta Specifications and Lowndes County Standard Specifications Section 02665 whichever is more stringent. Provide an accurate pressure gauge with graduation not greater than 5 psi.
D. All valves and valve boxes shall be properly located and installed and operable prior to testing. Bulkheads shall be provided with a sufficient number of outlets for filling and draining the line and for venting air.
E. Hydrostatic pressure and leakage tests shall conform with Section 4 of AWWA C600. Furnish gauges, meters, pressure pumps and other equipment needed to fill the line slowly and perform the required hydrostatic pressure leakage tests.
F. The Owner will provide a source of supply from the existing finished water distribution system for Contractor’s use in filling the lines. An air break shall be maintained at all times between the Owner's distribution system and the Contractor’s equipment to prevent cross-connection. The line shall be slowly filled with water and the specified test pressure shall be maintained in the pipe for the entire test period by means of a pump furnished by the Contractor. Provide accurate means for measuring the quantity of water required to maintain this pressure. The amount of water required is a measure of the leakage.
G. Duration of pressure test shall not be less than 2 hours. The leakage test shall be a separate test following the pressure test and shall not be less than 2 hours duration. All leaks evident at the surface shall be repaired and leakage eliminated regardless of the total leakage as shown by test. Lines which fail to meet tests shall be repaired and retested as necessary until test requirements are complied with. Defective materials, pipes, valves and accessories shall be removed and replaced.
H. The Owner shall supply, at no cost to the Contractor, the water required for the pressure test and the leakage test.
3.06 DISINFECTION
A. Before being placed in service and after successful pressure testing, all new water pipelines shall be chlorinated using the continuous feed method specified in AWWA C651. The Contractor shall also follow the City of Valdosta Specifications and Lowndes County Standard Specifications Section 02665 whichever is more stringent. The Contractor shall submit a written procedure for the Engineer’s approval at least 15 days before the start of the disinfection at any section of the water main. The submitted procedure should also include the steps to be taken for the neutralization of the chlorinated water.
B. The location of the chlorination and sampling points will be determined by the Engineer in the field. Taps for chlorination and sampling shall be installed by the Contractor. The Contractor shall uncover and backfill the taps as required.
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C. The general procedure for chlorination shall be first to flush all dirty or discolored water from the lines and then introduce chlorine to achieve a concentration of at least 65 mg/l free chlorine in new line. The chlorine solution shall remain in the pipeline for 24 hours. Chlorine concentration shall be recorded at every outlet along the line at the beginning and end of the 24 hr period. All samples of water shall contain at least 10 mg/l free chlorine after 24 hours. Rechlorinate if required results are not obtained.
D. Following the chlorination period, all treated water shall be flushed from the lines at their extremities and replaced with water from the distribution system. Prior to flushing, chlorine residual shall be reduced to less than 1 mg/l. All chlorinated water flushed from the lines shall be disposed of by discharging to the nearest sanitary sewer or by other approved means. No discharge to any storm sewer or natural water course will be allowed. Flush all lines until residual is equal to existing system.
E. Bacteriological sampling and analysis of the replacement water may then be made. City of Valdosta Water Treatment Plant personnel shall collect samples from the line and test for bacteriological quality in accordance with the rules of the Georgia Department of Natural Resources, Environmental Protection Division and in full accordance with AWWA C651. At least one set of samples shall be collected at every 1,200 feet, plus one set from the end of the line and at least one set from each branch and dead-end.
F. The Contractor shall give the Owner and the Engineer 48-hour written notice of the planned bacteriological testing. The Engineer must be present when samples are taken. City of Valdosta has its own laboratory to test bacteriological quality. The bacteriological samples shall be analyzed for both coliform and non-coliform growth. If the criteria stated by the Georgia Department of Natural Resources are not obtained that section of the pipeline shall be rechlorinated.
G. Special disinfecting procedures shall be used in connections to existing mains and where the method outline above is not practical.
END OF SECTION
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SECTION 02620
HIGH DENSITY POLYETHYLENE PIPE AND FITTINGS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment, and incidentals required to install High Density Polyethylene (HDPE) pressure pipe, fittings, and appurtenances as shown on the Drawings and specified in the Contract Documents.
B. High Density Polyethylene (HDPE) – Lee County Utilities has the option of approving the use of HDPE up to 12 inches in diameter for water main crossings of roadways, ditches, canals, and environmentally sensitive lands. HDPE water mains shall have the same equivalent internal diameter and equivalent pressure class rating as the corresponding PVC pipe, unless otherwise approved by Lee County Utilities. For all roadway crossings a steel or DR 11 HDPE casing pipe must be provided. The Department of Transportation having jurisdiction of said road and right-of-way must grant specific approval.
1.02 REFERENCED STANDARDS
A. All standard specifications, i.e., Federal, ANSI, ASTM, etc., made a portion of these Specifications by reference, shall be the latest edition and revision thereof.
1.03 QUALIFICATIONS
A. All HDPE pipe, fittings, and appurtenances shall be furnished by a single manufacturer who is fully experienced, reputable and qualified in the manufacture of the items to be furnished.
1.04 SUBMITTALS
A. Submit to the ENGINEER, a list of materials to be furnished, the names of the suppliers, and the appropriate shop drawings for all HDPE pipe and fittings.
B. Submit the pipe manufacturer's certification of compliance with the applicable sections of the Specifications.
C. Submit shop drawings showing installation method and the proposed method and specialized equipment to be used.
1.05 INSPECTIONS AND TESTS
A. All work shall be inspected by an Authorized Representative of the OWNER who shall have the authority to halt construction if, in his opinion, these specifications or standard construction practices are not being followed. Whenever any portion of these specifications is violated, the ENGINEER or his authorized representative shall, by written notice, order further construction to cease until all deficiencies are corrected.
1.06 WARRANTY AND ACCEPTANCE 5000-79695 02620-1 Florida Governmental Utilities Authority Waterway Estates Interconnect 60% Submittal
A. Warrant all work to be free from defects in workmanship and materials for a period of one year from the date of completion of all construction. If work meets these specifications, a letter of acceptance, subject to the one year warranty period, shall be given at the time of completion. A final acceptance letter shall be given upon final inspection at the end of the one year warranty period, provided the work still complies with these specifications. In the event deficiencies are discovered during the warranty period, they shall be corrected by the CONTRACTOR without additional charge to the OWNER before final acceptance. During the warranty period, the ENGINEER shall determine if warranty repairs or replacement work shall be performed by the CONTRACTOR. The decision of the ENGINEER shall be binding upon the CONTRACTOR.
PART 2 PRODUCTS
2.01 POLYETHYLENE PIPE AND FITTINGS
A. Polyethylene pressure pipe shall be manufactured from PE3408 polyethylene and shall meet AWWA C906 standards. When specified by the ENGINEER on the construction drawings, as an alternate to PVC, HDPE, Ductile iron pipe sized (DIPS) piping can be used for buried applications. Iron pipe sized (IPS) HDPE piping can be used for above-ground applications. HDPE (IPS) SDR-11 Hydrostatic Design Basis (HDB) piping shall be used for the riser pipes from the pump discharge and manifold as shown on the drawings.
B. Where HDPE pipe is joined to HDPE pipe, it shall be by thermal butt fusion. Thermal fusion shall be accomplished in accordance with the pipe manufacturer and fusion equipment supplier specifications. The CONTRACTOR installing thermal butt fused HDPE pipe shall have a minimum of five years experience performing this type of work.
C. Qualification of Manufacturer: The Manufacturer shall have manufacturing and quality control facilities capable of producing and assuring the quality of the pipe and fittings required by these specifications. The Manufacturer's production facilities shall be open for inspection by the OWNER or his authorized representative. Qualified manufacturers shall be approved by the OWNER.
D. Approved Manufacturer: Manufacturers that are qualified and approved are listed below:
PLEXCO Division of Chevron Chemical Company DriscoPipe, Phillips Petroleum Co.
E. Materials: Materials used for the manufacture of polyethylene pipe and fittings shall be PE3408 high density polyethylene meeting cell classification 345434C or 345434E per ASTM 0 3350; and meeting Type III, Class B or Class C, Category 5, Grade P34 per ASTM 0 1248; and shall be listed in the name of the pipe and fitting manufacturer in PPI (Plastics Pipe Institute) TR-4, Recommended Hydrostatic Strengths and Design Stresses for Thermoplastic Pipe and Fittings Compounds, with a standard grade rating of 1600 psi at 73'F. The Manufacturer shall certify that the materials used to manufacture pipe and fittings meet these requirements.
F. Interchangeability of Pipe and Fittings: Polyethylene pipe and fittings shall be produced by the same Approved Manufacturer. Products made by subcontractor's or Manufacturer's 5000-79695 02620-2 Florida Governmental Utilities Authority Waterway Estates Interconnect 60% Submittal
distributor are not acceptable. Pipe and fittings from different Approved Manufacturers shall not be interchanged.
G. Polyethylene Pipe: Polyethylene pipe shall be manufactured in accordance with ASTM F 714, Polyethylene (PE) Plastic Pipe (SDR-PR) Based on Outside Diameter or ASTM 0 3035, Polyethylene (PE) Plastic Pipe (DR-PR) Based on Controlled Outside Diameter and shall be so marked. Each production lot of pipe shall be tested for (from material or pipe) melt index, density, % carbon, (from pipe) dimensions and either quick burst or ring tensile strength (equipment permitting).
H. Color Identification: HOPE must have at least three equally spaced horizontal colored marking stripes. Permanent identification of piping service shall be provided by adhering to the following colors (in accordance with the coloring code in Section 9900).
Blue – potable water Green – wastewater, sewage Pantone Purple – reuse or reclaimed water
I. Polyethylene Fittings and Custom Fabrications: Polyethylene fittings and custom fabrications shall be molded or fabricated by the pipe manufacturer. Butt fusion outlets shall be made to the same outside diameter, wall thickness, and tolerances as the mating pipe. All fittings and custom fabrications shall be fully rated for the same internal pressure as the mating pipe. Pressure de-rated fabricated fittings are prohibited.
J. Molded Fittings: Molded fittings shall be manufactured in accordance with ASTM 03261, Butt Heat Fusion Polyethylene (PEl Plastic Fittings for Polyethylene (PEl Plastic Pipe and Tubing, and shall be so marked. Each production lot of molded fittings shall be subjected to the tests required under ASTM D 3261.
K. X-Ray Inspection: The Manufacturer shall submit samples from each molded fittings production lot to x-ray inspection for voids, and shall certify that voids were not found.
L. Fabricated Fittings: Fabricated fittings shall be made by heat fusion joining specially machined shapes cut from pipe, polyethylene sheet stock, or molded fittings. Fabricated fittings shall be rated for internal pressure service equivalent to the full service pressure rating of the mating pipe. Directional fittings 16" IPS and larger such as elbows, tees, crosses, etc., shall have a plain end inlet for butt fusion and flanged directional outlets. Part drawings shall be submitted for the approval of the ENGINEER.
M. Polyethylene Flange Adapters: Flange adapters shall be made with sufficient through-bore length to be clamped in a butt fusion joining machine without the use of a stub-end holder. The sealing surface of the flange adapter shall be machined with a series of small v-shaped grooves to provide gasketless sealing, or to restrain the gasket against blow-out.
N. Back-up Rings and Flange Bolts: Flange adapters shall be fitted with lap joint flanges pressure rated equal to or greater than the mating pipe. The lap joint flange bore shall be chamfered or radiused to provide clearance to the flange adapter radius. Flange bolts and nuts shall be Grade 2 or higher.
2.02 MANUFACTURER'S QUALITY CONTROL
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A. The pipe and fitting manufacturer shall have an established quality control program responsible for inspecting incoming and outgoing materials. Incoming polyethylene materials shall be inspected for density, melt flow rate, and contamination. The cell classification properties of the material shall be certified by the supplier, and verified by Manufacturer's Quality Control. Incoming materials shall be approved by Quality Control before processing into finished goods. Outgoing materials shall be checked for:
• Outside diameter, wall thickness, and eccentricity as per ASTM D2122 at a frequency of at least once/hour or once/coil, whichever is less frequent. • Out of Roundness at frequency of at least once/hour or once/coil, whichever is less frequent. • Straightness, inside and outside surface finish, markings and end cuts shall be visually inspected as per ASTM F714 on every length of pipe.
Quality Control shall verify production checks and test for:
• Density as per ASTM D1505 at a frequency of at least once per extrusion lot. • Melt Index as per ASTM D1238 at a frequency of at least once per extrusion lot. • Carbon content as per ASTM 01603 at a frequency of at least once per day per extrusion line. • Quick burst pressure (sizes thru 4-inch) as per ASTM 01599 at a frequency of at least once per day per line. • Ring Tensile Strength (sizes above 4-inch equipment permitting) as per ASTM 02290 at a frequency of at least once per day per line. • ESCR (size permitting) as per ASTM F1248 at a frequency of at least once per extrusion lot.
X-ray inspection shall be used to inspect molded fittings for voids, and knit line strength shall be tested. All fabricated fittings shall be inspected for joint quality and alignment.
2.03 COMPLIANCE TESTS
A. In case of conflict with Manufacturer's certifications, the CONTRACTOR, ENGINEER, or OWNER may request re-testing by the manufacturer or have re-tests performed by an outside testing service. All re-testing shall be at the requestor's expense, and shall be performed in accordance with the Specifications.
B. Installation shall be in accordance with Manufacturer's recommendations and this specification. All necessary precautions shall be taken to ensure a safe working environment in accordance with the applicable codes and standards.
PART 3 EXECUTION
3.01 INSTALLATION OF HIGH OENSITY POLYETHYLENE PRESSURE PIPE AND FITTINGS
A. All high density polyethylene (HOPE) pressure pipe shall be installed by direct bury, directional bore, or a method approved by the OWNER/ENGINEER prior to construction. If directional bore is used, or if directed by the OWNER/ENGINEER, the entire area of construction shall be surrounded by silt barriers during construction. 5000-79695 02620-4 Florida Governmental Utilities Authority Waterway Estates Interconnect 60% Submittal
Installation shall be in accordance with Manufacturer's recommendations, and this specification. All necessary precautions shall be taken to ensure a safe working environment in accordance with the applicable codes and standards.
3.02 HEAT FUSION JOINING
A. Joints between plain end pipes and fittings shall be made by butt fusion, and joints between the main and saddle branch fittings shall be made using saddle fusion using only procedures that are recommended by the pipe and fitting Manufacturer. Ensure that persons making heat fusion joints have received training and certification for heat fusion in the Manufacturer's recommended procedure. Maintain records of trained personnel, and shall certify that training was received not more than 12 months before commencing construction. External and internal beads shall not be removed.
3.03 MECHANICAL JOINING
A. Polyethylene pipe and fittings may be joined together or to other materials by means of flanged connections (flange adapters and back-up rings) or mechanical couplings designed for joining polyethylene pipe or for joining polyethylene pipe to another material. Mechanical couplings shall be fully pressure rated and fully thrust restrained such that when installed in accordance with manufacturer's recommendations, a longitudinal load applied to the mechanical cooling will cause the pipe to yield before the mechanical coupling disjoins. External joint restraints shall not be used in lieu of fully restrained mechanical couplings.
3.04 BRANCH CONNECTIONS
A. Branch connections to the main shall be made with saddle fittings or tees. Polyethylene saddle fittings shall be saddle fused to the main pipe.
3.05 EXCAVATION
A. Trench excavations shall conform to this specification, Section 2222, the plans· and drawings, as otherwise authorized in writing by the ENGINEER or his approved representative, and in accordance with all applicable codes. Excess groundwater shall be removed by the CONTRACTOR. Where necessary, trench walls shall be shored or reinforced.
3.06 LARGE DIAMETER FABRICATED FITTINGS
A. Fabricated directional fittings 16" IPS and larger shall be butt fused to the end of a pipe. The flanged directional outlet connections shall be made up in the trench.
3.07 MECHANCIAL JOINT AND FLANGE INSTALLATION
A. Mechanical joints and flange connections shall be installed in accordance with the Manufacturer's recommended procedure. Flange faces shall be centered and aligned to each other before assembling and tightening bolts. In no case shall the flange bolts be used to draw the flanges into alignment. Bolt threads shall be lubricated, and flat washers shall be fitted under the flange nuts. Bolts shall be evenly tightened according to the tightening pattern and torque step recommendations of the Manufacturer. At least one hour after initial assembly, flange connections shall be retightened following the tightening pattern and torque step 5000-79695 02620-5 Florida Governmental Utilities Authority Waterway Estates Interconnect 60% Submittal
recommendations of the Manufacturer. The final tightening torque shall be 100 ft-lbs or less as recommended by the Manufacturer.
3.08 FOUNDATION AND BEDDING
A. Pipe shall be laid on grade and on a stable foundation in accordance with Section 2223.
3.09 PIPE HANDLING
A. When lifting with slings, only wide fabric choker slings shall be used to lift, move, or lower pipe and fittings. Wire rope or chain shall not be used. Slings shall be of sufficient capacity for the load, and shall be inspected before use. Worn or defective equipment shall not be used.
3.10 TESTING
A. Butt Fusion Testing: On every day butt fusions are to be made, the first fusion of the day shall be a trial fusion. The trial fusion shall be allowed to cool completely, then fusion test straps shall be cut out. The test strap shall be 12 inches (min) or 30 times the wall thickness in length with the fusion in the center, and 1 inch (min) or 1.5 times the wall thickness in width. Bend the test strap until the ends of the strap touch. If the fusion fails at the joint, a new trial fusion shall be made, cooled completely, and tested. Butt fusion of pipe to be installed shall not commence until a trial fusion has passed the bent strap test.
Perform all butt fusion joints in the presence of the ENGINEER or his representative. Record the temperature and corresponding time for each fusion joint.
B. Hydrostatic Pressure Testing: HDPE pipes shall be pressure tested in a similar manner as for PVC force main in accordance with Section 01660.
END OF SECTION
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SECTION 02622
POLYVINYL CHLORIDE (PVC) FORCE MAIN PIPE
PART 1 GENERAL
1.1 SCOPE OF WORK
A. Furnish all labor, materials, equipment, and incidentals required, and install polyvinyl chloride (PVC) force main pipe, fittings, and appurtenances a shown on the drawings and as specified herein.
1.2 SUBMITTALS
A. Submit to the ENGINEER within fourteen calendar days after receipt of Notice-to-Proceed a list of materials to be furnished, the names of the suppliers and the date of delivery of materials to the site.
B. Submit for approval, as provided in the General Conditions, complete, detailed shop drawings of all PVC pipe and fittings.
C. Submit and shall comply with pipe manufacturer's recommendations for handling, storing, and installing pipe and fittings.
PART 2 PRODUCTS
2.1 POLYVINYL CHLORIDE (PVC) PIPE AND FITTINGS
A. Unless otherwise shown on the Drawings or specified, PVC force main pipe shall meet the following minimum requirements:
1. For PVC pipe not installed under roadway pavement:
a. Pipe 4 inches through 12 inches in diameter shall be DR18, AWWA C-900.
b. Pipe 14 inches through 24 inches in diameter shall be DR25, AWWA C905.
2. For PVC pipe installed under roadway pavement by direct burial:
a. Pipe 4 inches through 12 inches in diameter shall be DR14, AWWA C-900
b. Pipe 14 inches through 24 inches in diameter shall be DR18, AWWAC905.
c. Pipe greater than 24 inches in diameter shall be DR25, AWWA C-905.
B. PVC fittings 4 inches and larger in diameter shall meet the requirements of applicable AWWA C900 and C905 specifications. Fittings shall be ductile iron fittings with mechanical or push on joints conforming to AWWA C153 or C110. Ductile iron fittings shall have a fusion bonded epoxy coating to a minimum of 20 mil thickness. 5000-79695 02622-1 Florida Governmental Utility Authority Waterway Estates Interconnect 60% Submittal
C. Pipe shall be homogeneous throughout. It shall be free from voids, inclusions, and other defects. Pipe surface shall be free from nicks and scratches, joining surfaces of spigots and joints shall be free from gouges and imperfections that could cause leakage.
D. All joints shall be made in accordance with the manufacturer's recommendations. The particular joint used shall be approved by Lee County Utilities prior to installation. No sulfur-based compounds shall be used.
E. Pipe shall be furnished in standard laying lengths not exceeding 20 feet.
F. Restrained joints shall be provided at all tees, plugs, horizontal bends, vertical offsets, and locations shown on the drawings. Joint restraint devices for C-900, C905 PVC pipe used with ductile iron mechanical joint fittings shall be EBAA Iron Inc., Series 2000 PV, Un i-Flange 1300, Star Pipe Product, L.P., or approved equal. Bell joint restraint devices for PVC push joint pipe shall be EBAA Iron Inc., Series 1600 for C- 900 PVC pipe, Series 2800 for bell restraint on C- 905 PVC pipe or Uni-Flange Series 1300, 1360 or 1390 or ROMAC Series 600, Star Pipe Products L.P., or approved equal. Bolts and nuts shall be Ductile Iron or 300 Series Stainless Steel, T-Head type with hexagonal nuts. Bolts and nuts shall be machined through and nuts shall be tapped at right angles to a smooth bearing surface. Restraints shall be Class 150 psi and shall be capable of Withstanding 300 psi quick burst test without separation or failure. Suitable PVC/ductile iron adapters shall be provided as necessary.
G. PVC pipe fittings for 2-inch and smaller diameter pipe shall be glued and shall be Schedule 80 and conform to the requirements of ASTM 0-2464. Threaded joints can be used with PVC Schedule 80 pipe or stronger with diameters larger than 2 inches. At threaded joints between PVC and metal pipes, the metal shall contain a threaded socket end and the PVC threaded spigot end. A metal spigot shall not under any circumstances, be screwed into a PVC socket.
2.2 IDENTIFICATION
A. Pipe shall bear identification markings that will remain legible after normal handling, storage, and installation. Markings shall be applied in a manner that will not weaken or damage the pipe. Marking shall be applied at intervals of not more than 5 feet on the pipe. Marking on the pipe shall include the following:
B Nominal size and 00 base.
C. PVC.
D. Dimension ratio.
E. AWWA pressure rating.
F. AWWA designation.
G. Manufacturer's name or trademark.
H. Manufacturer's production code, including day, month, year, shift, plant, and extruder of manufacture.
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I. All PVC sewage force main pipe shall be color coded green.
2.3 STRUCTURE AND MANHOLE CONNECTIONS
A. Pipe stubs for all structure and manhole connections shall not exceed 12 inches in length unless otherwise shown on the drawings. Caps shall be furnished were required.
PART 3 EXECUTION
3.1 INSTALLATION
A. PVC force main pipe shall be installed in accordance with the manufacturer's recommendation, as shown on the Drawings, and as specified herein.
B. Use care in handling, storage, and installation of pipe and fittings. Storage of pipe on the job site shall be done in accordance with the pipe manufacturer's recommendation. Under no circumstances shall pipe or fittings be dropped into the trench.
C. Pipe shall be laid to lines and grade shown on the Drawings with bedding and backfill as shown on the Drawings and as specified in Section 02221. Blocking under the pipe will not be permitted.
D. When laying is not in progress, or the potential exists for dirt or debris to enter the pipe, the open ends of the pipe shall be closed with plug or by other approved means.
E. In all cases where PVC pipe is installed, identification tape shall be located above the top of the pipe as shown on the Drawings.
3.2 TESTING FORCE MAINS
A. Test force mains for leakage in accordance with Section 01660.
END OF SECTION
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SECTION 02640
VALVES, HYDRANTS AND APPURTENANCES
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required to provide all buried valves, valves in manholes and underground vaults, hydrants and appurtenances complete with actuators and all accessories as shown on the Drawings and as specified herein.
1.02 RELATED WORK
A. Trenching, backfilling and compaction are included in Section 02221.
B. Concrete is included in Division 3.
1.03 SUBMITTALS
A. Submit materials required to establish compliance with these Specifications in accordance with Section 01300 for shop drawings. Submittals shall include the following:
1. Manufacturer's literature, illustrations, specifications and engineering data including:
a. Dimensions
b. Size
c. Materials of construction
d. Weight
e. Protection coating
f. Actuator weight
g. Calculations for actuator torque where applicable
B. Test Reports
1. Four copies of all certified shop test results specified herein.
C. Operation and Maintenance Manuals
1. Submit complete operation and maintenance manuals including copies of all approved Shop Drawings.
D. Certificates
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1. Certificates of compliance where required by referenced standards: For each valve specified to be manufactured and/or installed in accordance with AWWA and other standards, submit an affidavit of compliance with the appropriate standards, including certified results of required tests and certification of proper installation.
1.04 REFERENCE STANDARDS
A. Comply with applicable provisions and recommendations of the following, except as otherwise shown or specified.
B. American Water Works Association (AWWA)
1. AWWA C111 - Rubber-Gasket Joints for Ductile-Iron and Pressure Pipe and Fittings.
2. AWWA C500 - Metal-Seated Gate Valves, for Water Supply Service.
3. AWWA C502 - Dry-Barrel Fire Hydrants.
4. AWWA C504 - Rubber-Seated Butterfly Valves.
5. AWWA C509 - Resilient-Seated Gate Valves for Water Supply Service.
6. AWWA C517 – Resilient-Seated Cast Iron Eccentric Plug Valves
C. American National Standards Institute (ANSI)
1. ANSI B16.1 - Cast-Iron Pipe Flanges and Flanged Fittings.
D. American Society for Testing and Materials (ASTM)
1. ASTM A48 - Standard Specification for Gray Iron Castings.
2. ASTM A126 - Standard Specification for Gray Iron Castings for Valves, Flanges and Pipe Fittings.
3. ASTM A153 - Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware.
4. ASTM A276 - Standard Specification for Stainless and Heat-Resisting Steel Bars and Shapes.
5. ASTM A536 - Standard Specification for Ductile Iron Castings.
E. Steel Structures Painting Council (SSPC)
1. SSPC SP-6 - Surface Preparation Specification No.6 Commercial Blast Cleaning
F. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.
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1.05 QUALITY ASSURANCE
A. Manufacturer's Qualifications
1. Valves and appurtenances provided under this Section shall be the standard product in regular production by manufacturers whose products have proven reliable in similar service for at least five years. If required, the manufacturer shall furnish evidence of installation in satisfactory operation.
2. All units of the same type shall be the product of one manufacturer.
B. Design Criteria
1. All valves and appurtenances shall be new and in perfect working condition. Valves shall be designed for continuous use with a minimum of maintenance and service required and shall perform the required function without exceeding the safe limits for stress, strain or vibration. In no case will used or damaged valves be acceptable. The selection of equipment to meet the specified design conditions is the responsibility of the Contractor. Both workmanship and material shall be of the very best quality and shall be entirely suitable for the service conditions specified.
C. Source Quality Control
1. Valves shall be shop tested in accordance with the following:
a. Gate valves: AWWA C500
b. Rubber-seated butterfly valves: AWWA C504
c. Plug Valves: AWWA C517
2. Obtain each type of valve from no more than one manufacturer.
1.06 SYSTEM DESCRIPTION
A. Plug valves shall be compatible with sanitary sewer service, gate valves and butterfly valves shall be compatible for use in potable water service.
1.07 DELIVERY, STORAGE AND HANDLING
A. Deliver materials to the site to ensure uninterrupted progress of the work.
B. Protect threads and seats from corrosion and damage. Rising stems and exposed stem valves shall be coated with a protective oil film which shall be maintained until time of use.
C. Furnish covers for all openings.
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1. All valves 3-in and larger shall be shipped and stored on site until time of use with wood or plywood covers on each valve end.
2. All valves smaller than 3-in shall be shipped and stored as above except that heavy card board covers may be furnished instead of wood.
D. Store equipment to permit easy access for inspection and identification. Any corrosion in evidence at the time of Owner acceptance shall be removed, or the valve shall be removed from the job.
E. Store all equipment in covered storage off the ground.
1.08 COORDINATION
A. Review installation procedures under other Sections and coordinate with the work which is related to this Section including buried piping installation, site utilities, and piping insulation.
B. Coordinate the location and placement of concrete thrust blocks when required.
PART 2 PRODUCTS
2.01 GENERAL
A. All buried valves shall open counter-clockwise.
B. The use of a manufacturer's name and/or model or catalog number is for the purpose of establishing the standard of quality and general configuration desired.
C. Valves shall be of the size shown on the Drawings or as noted and as far as possible equipment of the same type shall be identical and from one manufacturer.
D. Valves shall have the name of the maker, nominal size, flow directional arrows, working pressure for which they are designed and standard to which they are manufactured cast in raised letters on some appropriate part of the body.
E. Unless otherwise noted, valves shall have a minimum working pressure of 150 psi or be of the same working pressure as the pipe they connect to, whichever is higher, and suitable for the pressures noted where they are installed.
F. Valves shall be of the same nominal diameter as the pipe or fittings they are connected to. Except as otherwise noted, joints shall be mechanical joints, with joint restraint.
G. Valves shall be especially constructed for buried service.
2.02 VALVE BOXES
A. All valves shall be provided with extension shafts, operating nuts and valve boxes as follows:
1. Extension shafts shall be Type 304 stainless steel and the operating nut shall be 2-in square. Shafts shall be designed to provide a factor of safety of not less than four. Operating nuts
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shall be pinned to the shafts. Extension shafts shall be equal to Mueller A-26441 or M & H Valve Style 3801.
2. Top of the operating nut shall be located 2-in below the rim of the valve box.
3. Valve boxes shall be as manufactured by U.S. Foundry No. 7500, Mueller H-10360 or equal and shall be a heavy-pattern cast iron, two-piece, telescoping type box with dome base suitable for installation on the buried valves. Inside diameter shall be at least 5-1/4-in. Barrel length shall be adapted to the depth of cover, with a lap of at least 6-in when in the most extended position. Covers shall be cast iron with integrally-cast direction-to-open arrow and the words “WATER” or “WATER VALVE” for a potable water valve or "SANITARY" or "SSANITARY VALVE" for a force main valve. Aluminum or plastic are not acceptable. A means of lateral support for the valve extension shafts shall be provided in the top portion of the valve box.
4. The upper section of each box shall have a bottom flange of sufficient bearing area to prevent settling. The bottom of the lower section shall enclose the stuffing box and operating nut of the valve and shall be oval.
5. A position-indicating device shall be provided for each valve. The position-indicating device shall be Westran Model 128, Pratt Diviner, or equal, which shall mount over the shaft and visually show the position of the valve at all times. All material shall be noncorrosive, nonmagnetic and shall require no lubrication. Unit shall be furnished and arranged for use with the valve box. The required valve box adapters and cover shall be furnished.
6. An approved operating key or wrench shall be furnished.
7. All fasteners shall be Type 304 stainless steel.
2.03 RESILIENT SEATED GATE VALVES
A. Valves shall be manufactured in accordance with AWWA C509, by Mueller or M&H Valve Company or approved equal.
B. Valves shall be provided with a minimum of two O-ring stem seals.
C. Bonnet and gland bolts and nuts shall be either fabricated from a low alloy-steel for corrosion resistance or electroplated with zinc or cadmium. The hot-dip process in accordance with ASTM A153 is not acceptable.
D. Wedges shall be totally encapsulated.
E. Units shall be, in addition, UL and FM approved.
2.04 TAPPING SLEEVES AND TAPPING VALVES
A. Tapping sleeves shall be cast or ductile iron of the split sleeve, mechanical joint type designated for working pressure not less than 200 psi. Armored end gaskets shall be provided for the full area of the sleeve flanges. Sleeves shall be as manufactured by Mueller or Ford FTS or approved equal. Nuts and bolts shall be Type 304 stainless steel.
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B. Tapping valves shall conform to the requirements specified above for gate valves except that one end shall be flanged connection to the tapping sleeve and one mechanical joint connection to the branch pipe. Tapping valves shall be provided with an oversized opening to permit the use of full size cutters.
2.05 BUTTERFLY VALVES
A. Valves shall be manufactured in strict accordance with AWWA C-504. Valves shall be bubble tight at rated pressures. Valve discs shall rotate 90 degrees from full closed to open. Operators shall be assembled to the valve by the valve manufacturer. The valve/operator shall be tested as a complete assembly by the valve manufacturer. The manufacturer shall have produced AWWA butterfly valves for a minimum of five years.
B. Valve bodies shall be constructed of cast iron ASTM A126 Class B. Valves in vaults shall be flanged. Flange drilling shall be in accordance with ANSI B16.1, Class 150. Laying length shall be short body as listed in AWWA C504. Buried valves shall be mechanical joint end conforming to ANSI C111.
C. Valve discs shall be constructed of cast iron ASTM A126, Class B or ductile iron ASTM A536. Disc edge shall be either ni-chrome or Type 316 stainless steel.
D. Rubber valve seats shall be Buna-N. The seat shall be located in the valve body. If seat retaining hardware such as screws and segments are used they shall be Monel. If screws are used, Monel plugs shall be affixed in the valve body and tapped to receive these screws.
E. Valve shafts shall be Type 304 stainless steel, ASTM A276 and shall be of a diameter not less than those listed in AWWA C504 Class 150B.
F. Shaft seals shall be furnished where the shaft projects thru the valve body. Shaft seals shall be standard split-v type packing.
G. Valves shall be fitted with sleeve type bearings contained in the trunions of the valve body. Bearing material shall be nylon for valves thru 20-in and fiberglass with Teflon lining for valves 24-in and larger.
H. Valve manufacturer shall furnish and mount operator suitable for buried service. Operators shall be self-locking and suitable for submergence to 20-ft. A 2-in square operating nut shall be furnished. Operator stops shall be capable of withstanding an input torque of 450 ft. (minimum) lbs.
I. All valves shall be hydrostatically and leak tested.
J. Valve class shall be AWWA Class 150B with operators sized for bi-directional flow.
K. Valves shall be Groundhog by Henry Pratt or manufactured by M&H or DeZurik valve companies or Val-matic.
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2.06 PLUG VALVES
A. Plug valves specified herein shall be suitable for buried service, and shall be Series PEC by DeZurik Water Controls of Sartell, Minnesota; the Cam-Centric® by Val-Matic Valve and Manufacturing Corporation of Elmhurst, Illinois, or Model F5413 by Clow Valve Company (A Division of McWane Inc.) of Oskaloosa, Iowa. Plug valves shall conform to the minimum requirements of AWWA C517, in addition to the requirements specified herein.
B. All plug valves shall be of the non-lubricated, eccentric type with bodies and plugs of semi-steel construction. Valves shall be rated for a minimum working pressure of 175 psig for 3-in through 12-in and 150 psig for 14-in through 72-in valves. The area at the valve port shall be at least 80 percent of the full pipe area.
C. All plug valves for whatever service, shall be capable of passing “pigging” cleaning equipment (using a Girard or similar cleaning pig of full nominal pipeline diameter) in either direction and manufacturer shall so certify that this may be done without the use of special equipment.
D. Valves shall have balanced plugs with a resilient facing of Nitrile (Buna-N) solidly bonded thereto to assure bubble-tight shutoff low torque requirements.
E. Seats shall have a welded-in overlay of 90 percent pure nickel on all surfaces contacting the plug face.
F. Valves shall be furnished with bolted bonnets and self-adjusting chevron-type packing. Packing shall be replaceable without disassembling the valve or removing the bonnet from the valve.
G. Corrosion-resistant, permanently-lubricated bearings shall be provided at both ends of the valve shafts.
H. All valves shall be supplied with mechanical joint ends conforming to AWWA C111, unless otherwise noted herein.
I. All exterior hardware on valves shall be of Type 316 stainless steel.
2.07 AIR RELEASE VALVES
A. Air release valves shall comply with AWWA C-512.
B. The air release valves body and cover shall be cast iron with stainless steel float. Inlets and outlets to be furnished N.P.T.
C. The air release valves for the water main shall be capable of operating at pressures of at least 125 psi, have a -in diameter orifice outlet, 1-in inlet, and shall be Model 50 with accessories as manufactured by APCO Valve and Primer Corporation, Schaumburg, IL; or approved equal as manufactured by Val-Matic, Valve and Manufacturing Corp., Lyons, IL; or equal.
D. The appurtenant valves between the water main and the release valves shall be screwed end gate valves, bronze, solid wedge, rising-stem-type such as Fig. 47 manufactured by Jenkins Bros.; Crane, Fairbanks; Kennedy Valve Manufacturing Co. or equal.
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E. Appurtenant valves shall be furnished with handwheels that turn counter clockwise to open and have an arrow and the word OPEN cast thereon to indicate the direction of opening.
F. Pipe nipples, fittings, and supplemental piping for use in installing the air release valve shall be Schedule 40 galvanized steel.
2.08 CORPORATION STOPS
A. Corporation stops shall be ground key type, bronze with Mueller-type threads and suitable for the working pressure of the system. Corporation stops shall not be less than 1-in in diameter and shall be installed where shown, specified or required.
B. Threaded ends for inlet and outlet of corporation stops shall conform to AWWA C800; coupling nut for connection to flared copper tubing shall conform to ANSI B16.26.
C. Furnish corporation stops as manufactured by the following or equal:
1. Mueller Company, Figure H-10003 or H-15000.
2. Ford
2.09 CURB STOPS
A. Curb stops shall be bronze with copper fittings and shall be of the ground key type with base cap and stops.
B. Curb stops shall be furnished with curb boxes of the extension type with stationary rod and arch pattern base. Curb boxes shall be Mueller Figure H-10314 and shall be provided with lid, foot piece and one operating key.
2.10 SURFACE PREPARATION AND SHOP COATINGS
A. For all buried valves and hydrants, the valve body, bonnet and gland shall be coated with electrostatically applied, fusion bonded epoxy coating internally and externally to a minimum thickness of 8 mils. The epoxy shall be non-toxic, impart no taste to the water and meet or exceed the requirements of AWWA-C550 and the NSF.
B. Exterior ferrous metal surfaces of all buried valves and hydrants shall be blast cleaned in accordance with SSPC SP-6 and given two shop coats of a heavy coat tar enamel or an approved two-component coat tar epoxy paint.
C. Exterior ferrous metal surfaces of all nonburied valves shall be shop painted with one coat of primer in accordance with the requirements of Section 09901.
PART 3 EXECUTION
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3.01 INSPECTION AND PREPARATION
A. During installation of all valves and appurtenances, verify that all items are clean, free of defects in material and workmanship and function properly.
B. All valves shall be closed and kept closed until otherwise directed by the Engineer.
3.02 INSTALLATION OF BURIED VALVES AND VALVE BOXES
A. Buried valves shall be cleaned and manually operated before installation. Buried valves and valve boxes shall be set with the stem vertically aligned in the center of the valve box. Valves shall be set on a firm foundation and supported by tamping pipe bedding material under the sides of the valve. The valve box shall be supported during backfilling and maintained in vertical alignment with the top flush with finish grade. The valve box shall be set so as not to transmit traffic loads to the valve.
B. Before backfilling, all exposed portions of any bolts shall be coated with two coats of bituminous paint comparable to Bitumastic No. 50 by Kop-Coat, Inc.
C. Install valve floorstand operators with stainless steel bolts.
3.03 INSTALLATION OF TAPPING SLEEVES AND VALVES
A. The proper authority shall be contacted and their permission granted prior to tapping a "live" line. The required procedures and time table shall be followed exactly.
B. Installation shall be made under pressure and flow shall be maintained. The diameters of the tap shall be a minimum of 1/4-in less than the inside diameter of the branch line.
C. The entire operation shall be conducted by workers experienced in the installation of tapping sleeves and valves. The tapping machine shall be furnished by the Contractor.
D. Determine the location of the line to be tapped to confirm that the proposed location will be satisfactory and that no interference will be encountered such as joints or fittings. No tap or sleeve will be made closer than three feet from a pipe joint.
E. Tapping sleeve and valve with boxes shall be set squarely centered on the line to be tapped. Adequate support shall be provided under the sleeve and valve during the tapping operation. Thrust blocks or other permanent restraint acceptable to the Engineer shall be provided behind all tapping sleeves. Proper tamping of supporting pipe bedding material around and under the valve and sleeve is mandatory for buried installations.
F. After completing the tap, the valve shall be flushed to ensure that the valve seat is clean. All proper regulatory procedures (including disinfection) shall be followed exactly.
3.04 INSTALLATION OF FIRE HYDRANTS
A. After staking the location of hydrants, Contractor shall contact the Engineer for final approval of hydrant location regardless of location shown on construction drawings.
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B. Fire hydrants shall be bedded on a firm foundation. Hydrants and connecting pipe shall have at least the same depth of cover as the distributing pipe. A drainage pit as detailed on the Drawings shall be filled with screened gravel and compacted. During backfilling, additional screened gravel shall be brought up around and 6-in over the drain port. Each hydrant shall be set in true vertical alignment and properly braced.
C. Hydrants shall be restrained as shown on the Drawings.
D. The hydrant shall be tied to the pipe with suitable rods or clamps, galvanized, painted, or otherwise rustproof treated. Hydrant paint shall be touched up as required after installation.
E. All hydrants shall stand plumb and shall have their nozzles parallel with or at right angles to the roadway, with pumper nozzle facing the roadway, except that hydrants having two-hose nozzles 90 degrees apart shall be set with each nozzle facing the roadway at an angle of 45 degrees.
F. Fire hydrants shall be painted in accordance with Owner's standard practice, standard fire hydrant red.
3.05 AIR RELEASE VALVE INSTALLATION
A. Each air release valve and gate valve shall be installed where and as shown on the Drawings or as directed by the Engineer.
B. Install air valve with double stainless steel band saddle and corporation stop connected directly into saddle with no nipples. All 2-in and smaller piping associated with this installation shall be galvanized (SCH 40) or stainless steel. Piping larger than 2-in size shall be ductile iron.
C. The main valve assemblies shall be installed vertically plumb and shall be installed with an outlet riser pipe of the size specified capped with a 1/4 bend aligned so as to prevent the introduction of water or other foreign objects into the outlet pipe. Backflushing connections and appurtenant valves shall be 1-in diameter and shall be installed facing away from the manhole opening and rungs so as not to limit access.
D. The air release valve and the cleanout shall be installed within precast concrete manholes, as shown on the Drawings. Precast manholes shall be as specified in Section 03410. Cast-in-place concrete shall be as specified in Section 03300.
3.06 BURIED VALVES INSTALLATION
A. Buried valves and boxes shall be installed in conformance to AWWA C500 and C504, as applicable, except as specified herein. Valves shall be set with the operating stem vertically aligned in the center. Valves shall be set on a firm foundation and supported by tamping selected excavated material under and at the sides of the valve.
B. Valve boxes shall be installed vertically, centered over the operating nut, and the elevation of the top shall be adjusted to conform with the finished surface of roadway or other surface at the completion of the contract. Boxes shall be adequately supported during backfilling to maintain vertical alignment.
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3.07 FIELD TESTS AND ADJUSTMENTS
A. Conduct a functional field test of each valve, including actuators and valve control equipment, in presence of Engineer to demonstrate that each part and all components together function correctly. All testing equipment required shall be furnished by the Contractor.
3.08 MANUFACTURER'S SERVICE
A. Furnish the services of a qualified representative of the tapping equipment manufacturer to provide on-site instruction during wet tapping of the existing water mains indicated on the Drawings.
B. Following installation of the butterfly valves and gate valves, furnish the services of a qualified, factory-trained representative of the manufacturer of the respective valves, to check the installations before they are placed in operation, supervise initial operations and testing in the presence of the Engineer, instruct the plant personnel in care and maintenance of the equipment, and make all necessary field adjustments. A minimum of 5 days, which may not necessarily be consecutive, shall be provided for these services. In the event of trouble with the equipment, the representative of the respective manufacturer shall revisit the site as often as necessary until all troubles are corrected and the installation is entirely satisfactory.
END OF SECTION
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SECTION 02658
CONNECTIONS TO AND WORK ON THE EXISTING SYSTEM
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall supply all materials, equipment and labor required to construct and maintain all temporary connections and bypasses and construct the permanent connections to the new system as shown on the Drawings and as directed by the Engineer.
B. Should damage of any kind occur to the existing piping, the Contractor shall at his/her own expense, as part of the work under this Item, make repairs to the satisfaction of the Engineer.
C. The Contractor shall notify the Engineer immediately of any discrepancies in elevations of existing pipeline shown on the Drawings and those established during construction in order that the Engineer can make the necessary modifications.
D. All new pipe for connection shall conform to the pipe specifications in Section 02616.
1.02 RELATED WORK
A. Trenching, backfill and compaction are included in Section 02221.
B. Concrete is specified in Section 03300.
C. Submittals are specified in Section 01300.
PART 2 PRODUCTS (NOT USED)
PART 3 EXECUTION
3.01 MAINTAINING WATER SERVICE
A. The Contractor shall provide all labor, equipment and materials necessary to maintain existing service connections, including temporary bypasses and all disinfection testing that may be required to bacteriologically clear any temporary piping and shall provide assurances that repairs for interruption of service from the temporary service are available 24 hours a day/7 days a week.
B. All procedures for maintaining service must meet the approval of the Engineer and the Contractor shall be required to submit to the Engineer, for approval, a detailed written plan of all methods of flow maintenance ten days in advance of flow interruption.
END OF SECTION
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SECTION 02661
PIPELINE CLEANING
PART 1 GENERAL
1.01 REQUIREMENTS INCLUDED
A. The Contractor shall furnish all supervision, tools, equipment, materials, labor, and other incidental items required to thoroughly clean and flush all piping specified herein.
B. All piping specified herein shall be cleaned using blow-off valves as shown on the drawings.
C. Furnish all equipment, materials and labor to install temporary piping from the Owner's designated source of potable water to the location at which flushing of the pipelines will commence.
D. Furnish all equipment, materials and labor to install temporary piping required to direct all water used for flushing the pipelines to a disposal point designated by the Owner.
E. Provide all necessary radio communication units, job site transportation, and auxiliary centrifugal pumps for cleaning.
F. Piping to be cleaned and flushed shall include the following:
1. All underground finished water piping installed under this Contract extending from the City of Valdosta Water Treatment Plant to the existing 12” water main on Northside Drive.
1.02 SCHEDULE
A. All pipeline flushing specified herein shall be performed between the hours of 8:00 P.M. and 6:00 A.M.
1.04 WORKMANSHIP
A. The Contractor shall furnish the services of a specialty subcontractor for the proper cleaning and flushing of all pipelines specified herein.
B. The Contractor shall provide knowledgeable and experienced personnel for supervision of the entire pipeline cleaning.
C. The Contractor shall be certified and licensed by the State of Florida as an Underground Utility Contractor.
D. All personnel shall be trained and accredited to be in compliance with OSHA 29, CFR 1910.120, Health and Safety Training.
E. Furnish at the project in progress training to the Owner’s personnel to provide for future remedial cleaning or to implement a proper flushing program.
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PART 2 PRODUCTS (Not used.)
PART 3 EXECUTION
3.01 OWNER FURNISHED SERVICES
A. The Owner shall furnish all potable water for the cleaning and flushing procedures at no expense to the Contractor.
3.02 CONTRACTOR FURNISHED SERVICES
A. Accessibility to the pipelines shall be provided at points approved by the Engineer.
B. Excavations, temporary piping and fittings required for access to the pipelines to be cleaned, and restoration of excavations shall be performed and installed by the Owner.
C. Excavations shall provide access one foot (1') below the pipeline.
D. If required, sheeting, bracing, and other appropriate means, methods and techniques of maintaining excavations to prevent accidents, cave-ins, or breaking of the ground outside of the excavation area shall be provided by the Owner.
E. Accurate record drawing information for the pipeline detailing all valves, fittings and appurtenances, etc.
F. Sufficient labor and supervision necessary or required for the duration of the cleaning operation with valve keys for operation of the system.
G. Barricades, cones, lights and other traffic control items that may be required to conform to existing safety and traffic regulations.
END OF SECTION
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SECTION 02930
LAWN RESTORATION
PART 1 GENERAL
1.1 DESCRIPTION OF REQUIREMENTS
A. The work in this section consists of furnishing all labor, material and equipment to replace and maintain all areas disturbed during construction by establishing a stand of grass, within the areas called for by the furnishing and placing grass sod, or seeding, or seeding and mulching.
1.2 REFERENCE DOCUMENTS
A. The materials used in this work shall conform to the requirements of Florida Department of Transportation Standard Specifications for Road and Bridge Construction as follows:
1. Sod - Section 981-2 2. Fertilizer - Section 982 3. Water - Section 983
1.3 SUBMITTALS
A. Submit certifications and identification labels for all sodding supplied as specified in Section 01300.
PART 2 PRODUCTS
2.1 SODDING
A. Types: Sod may be of either St. Augustine or Argentine Bahia grass or as that disturbed, as established prior to construction. It shall be well matted with roots. When replacing sod in areas that are already sodded, the sod shall be the same type as the existing sod.
B. Sod shall be provided as required in accordance with Florida Department of Transportation Specifications 575 and 981. The CONTRACTOR shall furnish sod equal to and similar in type as that disturbed. Placement and watering requirements shall be in accordance with FDOT Specifications Section 575.
C. The sod shall be taken up in commercial-size rectangles, preferably 12-inch by 24- inch or larger, except where 6-inch strip sodding is called for.
D. The sod shall be sufficiently thick to secure a dense stand of live grass. The sod shall be live, fresh and uninjured at the time of planting. It shall have a soil mat of sufficient thickness adhering firmly to the roots to withstand all necessary handling. It shall be reasonably free of weeds and other grasses. It shall be planted as soon as possible after being dug and shall be shaded and kept moist from the time it is dug until it is planted.
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E. Sod should be handled in a manner to prevent breaking or other damage. Sod shall not be handled by pitch forks or by dumping from trucks or other vehicles. Care shall be taken at all times to retain the native soil on the roots of each sod roll during stripping and handling. Sod that has been damaged by handling during delivery, storage or installation will be rejected.
2.2 FERTILIZER
A. Chemical fertilizer shall be supplied in suitable bags with the net weight certification of the shipment. Fertilizer shall be 12-8-8 and comply with Section 982 of the FDOT Standard Specification for Road and Bridge Construction.
B. The numerical designations for fertilizer indicate the minimum percentages (respectively) of (1) total nitrogen, (2) available phosphoric acid and (3) water soluble potash, contained in the fertilizer.
C. The chemical designation of the fertilizer shall be 12-8-8, with at least 50 percent of the nitrogen from a nonwater-soluble organic source. The nitrogen source may be an unreaformaldehyde source provided it is not derived from a waste product of the plastic industry.
2.3 EQUIPMENT
A. The device for spreading fertilizer shall be capable of uniformly distributing the material at the specified rate.
2.4 NETTING
A. Netting is fabricated of material similar to Geoscope Landscape Fabric or approved equal.
2.5 GRASSING
A. The CONTRACTOR shall grass all unpaved areas disturbed during construction which do not require sod. All grassing shall be completed in conformance with FDOT Specifications Sections 570 and 981. The grassed areas shall be mulched and fertilized in accordance with FDOT Specifications.
B. Grass seed shall be Argentine Bahia, 60 #/acre March 1 to November 1, 50 #/acre with 20 #/acre of rye grass seed November 1 to March 1. Argentine Bahia seed shall be a scarified seed having a minimum active germination of 40% and total of 85%.
C. Mulch material shall be free of weeds and shall be oat straw or rye, Pangola, peanut, Coastal Bermuda, or Bahia grass hay.
2.6 TOPSOIL
A. Topsoil stockpiled during excavation may be used. If additional topsoil is required to replace topsoil removed during construction, it shall be obtained off site at no additional cost to the OWNER. Topsoil shall be fertile, natural surface soil, capable of producing all trees, plants, and grassing specified herein.
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2.7 MULCH
A. Mulch shall be fresh cypress mulch. Rate of application specified herein shall correspond to depth not less than 1-inch or more than 3-inches according to texture and moisture content of mulch material.
2.8 WATER
A. It is the CONTRACTOR'S responsibility to supply all water to the site, as required during seeding and sodding operations and through the maintenance period and until the work is accepted. The CONTRACTOR shall make whatever arrangements may be necessary to ensure an adequate supply of water to meet the needs for his work. He shall also furnish all necessary hose, equipment, attachments, and accessories for the adequate irrigation of lawns and planted areas as may be required. Water shall be suitable for irrigation and free from ingredients harmful to plant life.
PART 3 EXECUTION
3.1 SOD BED PREPARATION
A. Areas to be sodded and/or seeded shall be cleared no all rough grass, weeds, and debris, and brought to an even grade.
B. The soil shall then be thoroughly tilled to a minimum 8-inch depth.
C. The areas shall then be brought to proper grade, free of sticks, stones, or other foreign matter over 1-inch in diameter or dimension. The surface shall conform to finish grade, less the thickness of sod, free of water-retaining depressions, the soil friable and of uniformly firm texture.
3.2 INSPECTION
A. Verify that soil preparation and related preceding work has been completed.
B. Do not start work until conditions are satisfactory.
3.3 SOD HANDLING AND INSTALLATION
A. During delivery, prior to planting, and during the planting of sod areas, the sod panels shall at all times be protected from excessive drying and unnecessary exposure of the roots to the sun. All sod shall be stacked during construction and planting so as not to be damaged by sweating or excessive heat and moisture.
B. After completion of soil conditioning as specified above, sod panels shall be laid tightly together so as to make a solid sodded lawn area. On mounds and other slopes, the long dimension of the sod shall be laid perpendicular to the slope. Immediately following sod laying the lawn areas shall be rolled with a lawn roller customarily used for such purposes, and then thoroughly watered.
C. Sod shall be placed at all areas where sod existed prior to construction, on slopes of 3 horizontal on 1 vertical (3: 1) or greater, in areas where erosion of soils will occur, and as directed by the 5000-79695 02930-3 Florida Governmental Utility Authority Waterway Estates Interconnect 60% Submittal
ENGINEER. On areas where the sod may slide, due to height and slope, the ENGINEER may direct that the sod be pegged, with pegs driven through the sod blocks into firm earth, at suitable intervals.
3.4 USE OF SOD ON ROADWAY PROJECTS
A. In accordance with the FDOT District One Standard Practice, permanent green grass shall be established at the completion of roadway construction and maintenance work. The following shall apply to all restoration involving State or County roadways:
1. Sod in lieu of seed and mulch shall be used on all roadways with urban (raised curb) typical sections. 2. One inch water per week shall be required for a minimum of four (4) consecutive weeks for the purpose of establishing sod. This can be waived during construction, if and only if there is a minimum of one inch of rain per week on all sod on the project. 3. Sod shall be placed on slopes 1:3 or greater. Staked sod shall be placed on slopes 1:2 or greater. 4. On all curves with superelevation, sod shall be placed from the edge of pavement to the toe of slope on the downhill side(s) for the entire length of the superelevated roadway. On multi- lane divided rural facilities, sod shall be placed in the median and on the inside of the curve in the superelevated areas. This does not apply to reverse crowns. 5. For all projects with less than 10,000 square yards grass area, sod shall be used. 6. On tangent sections and on outside of curves, sod shall be used between the edge of pavement and a point 4 feet beyond the shoulder break point. 7. The entire width of sod should not exceed 15 feet from the edge of pavement. 8. Sod is to be used to eliminate narrow seed and mulch areas. Areas less than 6 feet in width shall be sodded. 9. Sod shall be placed around drainage structures as per the standard Indexes and extended to the edge of pavement.
3.5 SOD MAINTENANCE
A. The sod shall produce a dense, well established growth. The CONTRACTOR shall be responsible for the repair and re-sodding of all eroded or bare spots until project acceptance. Repair to sodding shall be accomplished as in the original work.
B. Sufficient watering shall be done by the CONTRACTOR to maintain adequate moisture for optimum development of the seeded and sodded areas. Sodded areas shall receive no less than 1.5 inches of water per week for at least 2 weeks. Thereafter, the CONTRACTOR shall apply water for a minimum of 60 days as needed until the sod takes root and starts to grow or until final acceptance, whichever is latest.
3.6 CLEANING
A. Remove debris and excess materials from the project site.
END OF SECTION
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SECTION 03100
CONCRETE FORMWORK
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required and design, install and remove formwork for cast-in-place concrete complete as shown on the Drawings and as specified herein.
B. Secure to forms or set for embedment all miscellaneous metal items, sleeves, reglets, anchor bolts, inserts, waterstops, fiberglass reinforced plastic components, hatches and other items furnished under other Sections and required to be cast into concrete.
1.02 RELATED WORK
A. Concrete reinforcement is included in Section 03200.
B. Concrete joints and joint accessories are included in Section 03250.
C. Cast-in-place concrete is included in Section 03300.
D. Concrete finishes are included in Section 03350.
E. Grout is included in Section 03600.
F. Modifications to existing concrete are included in Section 03740.
G. Miscellaneous metals are furnished under Sections 05500.
H. Anchor bolts for equipment are furnished under Divisions 11, 15 and 16.
1.03 SUBMITTALS
A. Submit, in accordance with Section 01300, shop drawings and product data showing materials of construction and details of installation for:
1. Form release agent
2. Form ties
3. Bond breakers
4. Void forms
5. Show locations of joints in formwork, locations of form ties and rustication pattern.
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6. Architectural concrete forming system. Show locations of joints in formwork, panel sizes, patterns and locations of form ties.
7. Location and sequence of concrete placement.
8. Formwork and shoring design calculations; fabrication and erection documents for formwork; and shoring, stripping criteria and reshoring procedures. These items shall be signed and sealed by the Registered Design Professional (RDP) specified under Paragraph 1.06B for review and approval. The submittal shall include drawings that clearly indicate the construction loads delivered to the structure due to the formwork, shoring, stripping and reshoring and other construction activities.
B. Review will be for appearance, performance and strength of the completed structure only. Approval by the Engineer will not relieve the Contractor of responsibility for the strength, safety or correctness of methods used, the adequacy of equipment, or from carrying out the work as shown on the Drawings and as specified herein.
C. Sample Substrate
1. Demonstrate to the Engineer on a designated area of the concrete substructure exterior surface that the form release agent will not impair the bond of paint, sealant, waterproofing, dampproofing, or other coatings and will not affect the forming materials.
D. Certificates
1. Submit completed PE Certification Form for design of formwork in accordance with Section 01300. The PE Certification Form shall be completed and stamped by a professional engineer registered in the State of Florida.
2. Certify that form release agent complies with Federal, State and local VOC limitations.
1.04 REFERENCE STANDARDS
A. American Concrete Institute (ACI)
1. ACI 301 - Specifications for Structural Concrete
2. ACI 303R - Guide to Cast-in-Place Architectural Concrete Practice.
3. ACI 318 - Building Code Requirements for Structural Concrete
4. ACI 347 - Guide to Formwork for Concrete
B. APA - The Engineered Wood Association (APA)
1. Material grades and designations as specified
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C. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.
1.05 QUALITY ASSURANCE
A. The form liner manufacturer's representative shall be on-site during the initial installation of the form liner to instruct the Contractor on the proper methods of application and use of the liner. The representative shall be available to answer any questions on the liner that the Engineer may have.
1.06 SYSTEM DESCRIPTION
A. Definitions:
1. Architectural concrete is defined as concrete for the following exposed reinforced concrete surfaces where architectural concrete is indicated on the Drawings:
a. Exterior: walls to 6-in below finish grade, beams, columns and underside of slabs.
b. Interior: walls, beams, columns and underside of slabs visible in the finished structures.
c. Open topped tanks to 1-ft below normal operating water level: Walls, beams, columns and underside of slabs.
2. Structural concrete is defined as concrete that is not architectural concrete.
B. Structural design responsibility: Contractor shall provide all forms and shoring designed by a professional engineer registered in the State of Florida. Design and erect formwork in accordance with the requirements of ACI 301, ACI 318 and ACI 347. Comply with all applicable regulations and codes. Consider any special requirements due to the use of plasticized and/or retarded set concrete.
PART 2 PRODUCTS
2.01 GENERAL
A. The usage of a manufacturer's name and model or catalog number is for the purpose of establishing the standard of quality and general configurations desired.
2.02 MATERIALS
A. Forms, General
1. Make forms for cast-in-place concrete of wood, steel or other approved materials, except as specified in Paragraphs 2.02.B and 2.02.C.2. Construct wood forms of sound lumber or plywood free from knotholes and loose knots. Construct steel forms to produce surfaces equivalent in smoothness and appearance to those produced by new plywood
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panels. Design and construct all forms to provide a flat, uniform concrete surface requiring no grinding, repairs, or finishing except as specified in Section 03350.
B. Forms for Exposed Structural Concrete
1. Make forms for all exposed and non-submerged exterior and interior concrete of new and unused Plyform exterior grade plywood panels manufactured in compliance with the APA and bearing the APA trademark. Provide B grade or better veneer with High Density Overlay on all faces to be in contact with concrete. Design and construct all forms to provide a flat, uniform concrete surface requiring no grinding, repairs, or finishing except as specified in Section 03350.
2. Provide rigid forms that will not deflect, move, or leak. Design forms to withstand the high hydraulic pressures resulting from rapid filling of the forms and heavy high frequency vibration of the concrete. Limit deflection to 1/400 of each component span. Lay out form joints in a uniform pattern.
3. Dress and match boards. Sand plywood smooth and fit adjacent panels with tight joints. Tape, gasket, plug, and/or caulk all joints and gaps in forms to provide watertight joints that will withstand placing pressures without exceeding specified deflection limit or creating surface patterns.
4. Provide ¾-inch chamfer on all corners unless otherwise indicated.
5. Provide forms for circular structures that conform to the circular shape of the structure and where applicable the existing structure below. Straight panels may be substituted for circular panels if the straight panels do not exceed two feet in width, nor deflect more than 3-1/2 degrees per joint, nor conflict with specific notes indicated and panels conform with the existing structure below.
C. Column Forms
1. Form rectangular columns as specified for exposed structural concrete. Provide 3/4-in chamfer on all corners unless otherwise indicated.
2. Form circular columns with steel, fiberglass reinforced plastic or seamless cardboard column forms. Provide continuous forms for the height of the column between construction joints indicated.
D. Provide rustications as indicated. Mill and plane smooth moldings for chamfers and rustications. Provide rustications and chamfer strips of nonabsorbent material, compatible with the form surface and fully sealed on all sides to prevent the loss of paste or water between the two surfaces.
E. Form Release Agent. Coat all form surfaces in contact with concrete with an effective, non-staining, non-residual, water based, bond-breaking form coating unless otherwise indicated or specified. Form release agent shall not impair the bond of paint, sealant, waterproofing, dampproofing or other coatings.
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F. For concrete surfaces which are to be painted, use forms with high density overlay or a similar material which does not require a form release agent unless the Contractor can substantiate to the satisfaction of the Engineer that the form release agent will not remain on the formed surface after it is stripped.
G. Forms for Architectural Concrete
1. Make forms for architectural concrete of new and unused steel or high density overlay plywood. Design and construct all forms to provide a flat, uniform concrete surface having the architectural features shown on the Drawings and requiring no grinding, repairs, or finishing except as specified in Section 03350.
2. Provide rigid forms for architectural concrete that will not deflect, move, or leak. Design forms to withstand the high hydraulic pressures resulting from rapid filling of the forms and heavy high frequency vibration of the concrete. Limit deflection to 1/400 of each component span. Lay out form joints in a uniform pattern or as indicated on the Drawings.
3. Dress and match boards. Sand plywood smooth and fit adjacent panels with tight joints. Tape, gasket, plug, and/or caulk all joints and gaps in forms to provide watertight joints that will withstand placing pressures without exceeding specified deflection limit or creating surface patterns.
4. Provide ¾-inch chamfer on all corners unless otherwise indicated.
H. Form Ties
1. Coil and Wire Ties: Provide ties manufactured so that, after removal of the projecting part, no metal remains within 1-1/2-in of the face of the concrete. The part of the tie to be removed shall be at least 1/2-in diameter or be provided with a plastic or wooden cone at least 1/2-in diameter and 1-1/2-in long. Provide cone washer type form ties in concrete exposed to view.
2. Flat Bar Ties for Panel Forms: Provide ties that have plastic or rubber inserts with a minimum depth of 1-1/2-in and manufactured to permit patching of the tie hole.
3. Provide ties for liquid retaining structures that have a steel waterstop tightly attached to each strut or that have a neoprene rubber washer on each strut.
4. Do not use common wire for form ties.
5. Alternate form ties consisting of tapered through-bolts at least 1-in in diameter at smallest end or through-bolts that utilize a removable tapered sleeve of the same minimum size may be used. Install in forms so that large end is, where applicable, on the liquid or backfilled side of the wall. Clean, fill and seal form tie hole with non-shrink cement grout to provide watertight form tie holes and make all repairs needed to make watertight.
6. Alternate form ties specified in Paragraph 2.02.H.5 may be used when forms are to be set against previously placed or existing concrete walls. Use in conjunction with cast-in
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threaded inserts or drilled-in threaded anchors so that no metal remains within expansion joint upon removal of tapered through bolt. Conform to requirements specified in Paragraph 2.02.H.5.
PART 3 EXECUTION
3.01 GENERAL
A. Provide forms for all cast-in-place concrete including sides of footings. Construct and place forms to provide concrete of the shape, lines, dimensions and appearance indicated.
B. Provide removable panels at the bottom of forms for walls and columns to allow cleaning, inspection and joint surface preparation. Provide closable intermediate inspection ports in forms for walls. Provide tremies and hoppers for placing concrete and to allow concrete sampling, prevent segregation and prevent the accumulation of hardened concrete on the forms and reinforcement above the fresh concrete.
C. Place molding, bevels, or other types of chamfer strips to produce blockouts, rustications, or chamfers as indicated on the Drawings or as specified herein. Provide chamfer strips at horizontal and vertical projecting corners to produce a 3/4-in chamfer. Provide rectangular moldings at locations requiring sealants where shown on the Drawings or specified herein.
D. Provide rigid forms to withstand construction loads and vibration and meeting specified deflection limits and tolerances. Construct forms so that the concrete will not be damaged by form removal.
E. Accessories which remain embedded in the concrete after formwork removal will be subject to the approval of the Engineer. Permanent embedments shall have sufficient concrete cover or be of suitable materials for the exposure condition as approved by the Engineer. Remove unsatisfactory embedded items at no additional cost to the Owner.
3.02 FORM TOLERANCES
A. Design, construct and surface forms in accordance with ACI 347 and meet the following additional requirements for the specified finishes.
B. Forms for Exposed Structural Concrete: Edges of all form panels in contact with concrete flush within 1/8-in and forms for plane surfaces plane within 1/8-in in 4-ft. Maximum deviation of the finished surface at any point not to exceed 1/4-in from the intended surface indicated. Arrange form panels symmetrically and orderly to minimize the number of seams. Provide tight forms to prevent the passage of mortar, water, and grout.
C. Formed Surface Not Exposed to View or Buried: Class "C" Surface per ACI 347.
D. Formed Surface Including Mass Concrete, Pipe Encasement, Electrical Raceway Encasement and Other Similar Installations: No minimum requirements for surface irregularities and surface alignment. The overall dimensions of the concrete shall be plus or minus 1-in from the intended surface indicated.
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E. Formed Surfaces to be Painted: Surface irregularities limited to 1/16-in at any point. Variation in alignment not to exceed 1/16-in per 4-ft. The maximum deviation of the finish surface at any point not to exceed 1/4-in from the intended surface indicated.
F. Architectural Concrete: Surface irregularities limited to 1/16-in at any point. Variation in alignment not to exceed 1/16-in per 4-ft. The maximum deviation of the finish surface at any point not to exceed 1/4-in from the intended surface as shown on the Drawings
3.03 FORM PREPARATION
A. Clean, repair, remove projecting nails and fill holes, and smooth protrusions on all form surfaces to be in contact with concrete before reuse. Do not reuse forms for exposed concrete unless a "like new" condition of the form is maintained that will produce surfaces equivalent in smoothness and appearance to those produced by new plywood panels.
B. Coat wood forms in contact with concrete using form release agent prior to form installation.
C. Clean steel forms by sandblasting or other method to remove mill scale and other ferrous deposits from the contact surface of all forms. Coat steel forms in contact with concrete using form release agent prior to form installation.
3.04 REMOVAL OF FORMS
A. Be responsible for all damage resulting from removal of forms and make repairs at no additional cost to the Owner. Leave in place forms and shoring for horizontal structural members in accordance with ACI 301 and ACI 347. Conform to the requirements for form removal specified in Section 03300.
3.05 INSPECTION
A. Notify the ENGINEER when the forms are complete and ready for inspection, at least six working hours prior to the proposed concrete placement. The Engineer will inspect the forms to ensure overall conformance with the contract documents.
B. Failure of the forms to comply with the requirements specified, or to produce concrete complying with requirements specified shall be grounds for rejection of that portion of the concrete work. Repair or replace rejected work as directed by the Engineer at no additional cost to the Owner. Such repair or replacement shall be subject to the requirements of these Specifications and approval of the Engineer.
END OF SECTION
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SECTION 03200
CONCRETE REINFORCEMENT
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required and install all concrete reinforcement complete as shown on the Drawings and as specified herein, including dowels embedded into concrete for masonry.
B. Furnish deformed steel reinforcement required to be entirely built into masonry construction specified in Section 04200.
1.02 RELATED WORK
A. Concrete formwork is included in Section 03100.
B. Concrete joints and joint accessories are included in Section 03250.
C. Cast-in-place concrete is included in Section 03300.
D. Precast, prestressed concrete is included in Section 03420.
E. Grout is included in Section 03600.
F. Modifications to existing concrete are included in Section 03740.
G. Masonry is included in Section 04200.
1.03 SUBMITTALS
A. Submit, in accordance with Section 01300, shop drawings and product data showing materials of construction and details of installation for:
1. Reinforcing steel. Drawings for fabrication, bending, and placement of concrete reinforcement shall conform to the recommendations of ACI 315 for placement drawings and as specified herein.
a. Placement drawings. For walls, show elevations from the outside, looking towards the structure, at a minimum scale of 1/4-in to one foot. For slabs, show top and bottom reinforcement on separate plan views, as needed for clarity. For beams and columns, show schedules with sections and/or elevations and stirrup/tie spacing. Show additional reinforcement around openings, at corners and at other locations indicated, diagrams of bent bars, arrangements and assemblies, all as required for the fabrication and placement of concrete reinforcement. Reference bars to the same identification marks shown on the bar bending details. Identify bars to have special coatings and/or to be of special steel or special yield strength.
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b. Bar bending details. Reference bars to the same identification marks shown on the placement drawings. Identify bars to have special coatings and/or to be of special steel or special yield strength.
2. Fiber reinforcement. Submit manufacturer's data for synthetic reinforcing fibers. Identify all placements that are to contain synthetic reinforcing fibers. The fiber length and amount of fibers per cubic yard to be used for each placement shall be noted. Submit two samples of synthetic reinforcing fibers.
B. Submit samples of each of the following items.
1. Two samples of each type of mechanical reinforcing steel coupling system.
C. Submit, in accordance with Section 01300, Test Reports of each of the following items.
1. Certified copy of mill test on each heat of each steel proposed for use showing the physical properties of the steel and the chemical analysis.
2. Welder's certification in accordance with AWS D1.4 when welding of reinforcement is indicated, specified, or approved.
3. Certified copy of test reports for each foreign manufactured steel proposed for use in the fabrication of reinforcement. The tests shall be specifically made for this project at the expense of the Contractor by a domestic independent testing laboratory certified to perform the tests. The testing shall be for conformity to the applicable ASTM Standard.
4. Certified copy of test results for compliance for all galvanized reinforcement and accessories. Test report shall indicate the weight of the nickel-zinc and the applicable ASTM Standard.
5. Certified copy of test results for compliance for all epoxy-coated reinforcement and accessories. Test report shall indicate the applicable ASTM Standard and the measured values.
1.04 REFERENCE STANDARDS
A. American Society for Testing and Materials (ASTM)
1. ASTM A82 - Standard Specification for Steel Wire, Plain, for Concrete Reinforcement.
2. ASTM A184 - Standard Specification for Welded Deformed Steel Bar Mats for Concrete Reinforcement.
3. ASTM A185 - Standard Specification for Steel Welded Wire Fabric, Plain, for Concrete Reinforcement.
4. ASTM A496 - Standard Specification for Steel Wire, Deformed, for Concrete Reinforcement.
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5. ASTM A497 - Standard Specification for Steel Welded Wire Fabric, Deformed, for Concrete Reinforcement.
6. ASTM A615 - Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement.
7. ASTM A704 - Standard Specification for Welded Steel Plain Bar or Rod Mats for Concrete Reinforcement.
8. ASTM A706 - Standard Specification for Low-Alloy Steel Deformed and Plain Bars for Concrete Reinforcement.
B. American Concrete Institute (ACI)
1. ACI 301 - Specifications for Structural Concrete.
2. ACI 315 - Details and Detailing of Concrete Reinforcement.
3. ACI 318 - Building Code Requirements for Structural Concrete.
4. SP-66 (ACI 315) ACI Detailing Manual.
C. Concrete Reinforcing Steel Institute (CRSI)
1. Manual of Standard Practice
D. American Welding Society (AWS)
1. AWS D1.4 Structural Welding Code - Reinforcing Steel
E. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.
1.05 QUALITY ASSURANCE
A. Fiber Reinforcement. Provide services of a Manufacturer's representative, with at least 2 years experience in the use of the synthetic reinforcing fibers for a preconstruction meeting and assistance during the first placement of the material.
1.06 DELIVERY, HANDLING AND STORAGE
A. Provide reinforcement free from mill scale, rust, mud, dirt, grease, oil, ice, or other foreign matter.
B. Ship and store reinforcement with bars of the same size and shape fastened in bundles with durable tags, marked in a legible manner with waterproof markings showing the same "mark" designations as those shown on the submitted placement drawings.
C. Store reinforcement off the ground, protect from moisture and keep free from rust, mud, dirt, grease, oil, ice, or other injurious contaminants.
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PART 2 PRODUCTS
2.01 MATERIALS
A. Provide new materials of domestic manufacture complying with the following material specifications.
B. Deformed Concrete Reinforcing Bars: ASTM A615, Grade 60 deformed bars.
C. Spiral Reinforcement
1. ASTM A615, Grade 60 for plain or deformed bars.
2. ASTM A82 for cold-drawn wire.
D. Welded Steel Wire Fabric: ASTM A185. Provide in flat sheets.
E. Welded Deformed Steel Wire Fabric: ASTM A497.
F. Welded Plain Bar Mats: ASTM A704 and ASTM A615 Grade 60 plain bars.
G. Reinforcing Steel Accessories
1. Plastic Protected Wire Bar Supports: CRSI Bar Supports, Class 1 - Maximum Protection.
2. Stainless Steel Protected Wire Bar Supports: CRSI Bar Supports, Class 2 - Moderate Protection with legs made wholly from stainless steel wire.
3. Precast Concrete Bar Supports: CRSI Bar Supports, Precast Concrete Bar Supports. Precast concrete blocks that have equal or greater strength than the surrounding concrete.
H. Tie Wire
1. Tie Wires for Reinforcement: 16-gauge or heavier black annealed wire.
I. Mechanical Reinforcing Steel Coupling System
1. Use only where indicated. Mechanical reinforcing steel coupling system shall be positive connecting taper threaded type employing a hexagonal coupler such as Lenton rebar splices as manufactured by Erico Products Inc., Solon, OH or equal. Coupling system shall meet all ACI 318 requirements. Bar ends must be taper threaded with coupler manufacturer's bar threader to ensure proper taper and thread engagement. Provide with cap on female end to exclude dirt, debris and wet concrete. Couplers shall be torqued to manufacturer's recommended value.
2. Unless otherwise noted on the Drawings, mechanical reinforcing steel coupling system shall produce a splice strength in tension or compression of not less than 125 percent of the ASTM specified minimum yield strength of the reinforcing bar. Base yield strength on Grade 60 reinforcing unless otherwise indicated or specified.
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3. Compression type mechanical splices shall provide concentric bearing from one bar to the other bar.
J. Fiber Reinforcement
1. Synthetic reinforcing fibers for concrete grout shall be 100 percent polypropylene collated, fibrillated fibers, Fibermesh 300 as manufactured by Propex Concrete Systems Corp, Chattanooga, TN, or equal. Fiber length and quantity for the concrete grout mix shall be in strict compliance with the manufacturer's recommendations as approved by the ENGINEER.
2.02 FABRICATION
A. Comply with the CRSI Manual of Standard Practice.
B. Bend bars cold. Do not straighten or rebend bars.
C. Bend bars around a revolving collar having a diameter not less than that recommended by the CRSI or ACI 318.
D. Saw cut bar ends that are to be butt spliced, placed through limited diameter holes in metal, or threaded. Terminate saw cut ends in flat surfaces within 1-1/2 degrees of a right angle to the axis of the bar.
E. Spirals
1. Provide a minimum of 1-1/2 finishing turns at the top and bottom.
2. Splices. Provide tension lap splices at least 48 bar diameters, but not less than 12-in in length. Do not use welded splices unless specifically approved by the Engineer.
3. Provide spacers as recommended by the CRSI.
PART 3 EXECUTION
3.01 INSTALLATION
A. Comply with the CRSI Manual of Standard Practice for surface condition, bending, spacing and tolerances of placement for reinforcement. Provide the amount of reinforcing indicated at the spacing and clearances indicated on the Drawings.
B. Determine clear concrete cover based on exposure to the environment. Unless indicated otherwise on the Drawings, provide the following minimum clear concrete cover over reinforcement:
1. Concrete cast against and permanently exposed to earth: 3-in
2. Concrete exposed to soil, water, sewage, sludge and/or weather:
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a. Slabs (top and bottom cover), walls: 2-in
b. Beams and columns (ties, spirals and stirrups): 2-in
3. Concrete not exposed to soil, water, sewage, sludge and/or weather:
a. Slabs (top and bottom cover), walls, joists, shells and folded plate members: 1-in
b. Beams and columns (ties, spirals and stirrups): 1-1/2-in
C. Coat uncoated reinforcement which will be exposed for more than 60 days after placement with a heavy coat of neat cement slurry.
D. Do not weld reinforcing steel bars either during fabrication or erection unless indicated on the Drawings or as specified herein, or unless prior written approval has been obtained from the Engineer. Remove immediately all bars that have been welded, including tack welds, without such approval.
E. Reinforcing steel interfering with the location of other reinforcing steel, piping, conduits or embedded items may be moved within the specified tolerances or one bar diameter, whichever is greater. Obtain the approval of the Engineer if greater displacement of bars to avoid interference is needed. Do not cut reinforcement to install inserts, conduits, mechanical openings or other items without the prior approval of the Engineer.
F. Secure, support and tie reinforcing steel to prevent movement during concrete placement. Secure dowels in place before placing concrete.
G. Do not field bend reinforcing unless indicated or specifically authorized in writing by the Engineer. Cold-bend bars indicated or authorized to be field bent around the standard diameter spool specified in the CRSI. Do not heat bars. Closely inspect the reinforcing steel for breaks. Replace, repair by cutting out damaged bars and splicing new bars using coupling sleeves filled with ferrous material, or otherwise repair damaged reinforcing bars as directed by the ENGINEER at no additional cost to the Owner. Do not bend reinforcement after it is embedded in concrete unless indicated on the Drawings.
3.02 REINFORCEMENT AROUND OPENINGS
A. Provide additional reinforcing steel on each side of the opening equivalent to one half of the cross-sectional area of the reinforcing steel interrupted by the opening unless indicated otherwise on the Drawings. Extend each end of each bar beyond the edge of the opening or penetration by the tension development length for that bar size.
3.03 SPLICING OF REINFORCEMENT
A. Provide splices as shown on the Drawings and as specified herein.
B. Splices Indicated as Compression Splices: Provide lap splice of 30 bar diameters, but not less than 12-in unless indicated otherwise on the Drawings. Base the lap splice length for column vertical bars on the bar size in the column above.
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C. All Other Splices: Provide tension lap splices in compliance with ACI 318. Stagger splices in adjacent bars where possible. Provide Class B tension lap splices at all locations unless otherwise indicated.
D. Splices in Circumferential Reinforcement in Circular Walls: Provide Class B tension lap splices and stagger as indicated.
E. Tension Members: Avoid splicing of reinforcing steel in concrete elements indicated as "tension members." However, if splices are required for constructability, splices in the reinforcement subject to direct tension shall be butted and joined with complete penetration welds to develop, in tension, at least 125 percent of the specified yield strength of the bar. Offset splices in adjacent bars the distance of a Class B splice or 30-in, whichever is greater.
F. Lap splices in welded wire fabric in accordance with the requirements of ACI 318 but not less than 12-in. Tie the spliced fabrics together with wire ties spaced not more than 24-in on center and lace with wire of the same diameter as the welded wire fabric. Offset splices in adjacent widths to prevent continuous splices.
G. Mechanical reinforcing steel coupling system shall be used only where shown on the Drawings. Offset splices in adjacent bars by at least 30 bar diameters. Mechanical reinforcing steel coupling system is only to be used for special splice and dowel conditions approved by the ENGINEER.
3.04 ACCESSORIES
A. Determine, provide and install accessories such as chairs, chair bars and the like to support the reinforcement providing the spacing and clearances indicated on the Drawings and prevent its displacement during the erection of the reinforcement and the placement of concrete.
B. Use precast concrete blocks where the reinforcing steel is to be supported over soil.
C. Use plastic protected bar supports or steel supports with plastic tips where the reinforcing steel is to be supported on forms for a concrete surface that will be exposed to weather, high humidity, or liquid (including bottom of slabs over liquid containing areas). Use stainless steel protected bar supports in walls, beams and elevated slabs. Use stainless steel supports or plastic tipped metal supports in all other locations unless otherwise noted on the Drawings or specified herein.
D. Provide #5 minimum size support bars. Do not reposition upper bars in a bar mat for use as support bars.
E. Alternate methods of supporting top steel in slabs, such as steel channels supported on the bottom steel or vertical reinforcing steel fastened to the bottom and top mats, may be used if approved by the Engineer.
3.05 INSPECTION
A. Notify the Engineer when the reinforcing is complete and ready for inspection, at least six working hours prior to the proposed concrete placement. Do not cover reinforcing steel with concrete until the installation of the reinforcement, including the size, spacing and position of
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the reinforcement has been inspected by the Engineer and the Engineer’s release to proceed with the concreting has been obtained. Keep forms open until the Engineer has completed inspection of the reinforcement.
END OF SECTION
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SECTION 03250
CONCRETE JOINTS AND JOINT ACCESSORIES
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required and install accessories for concrete joints complete as shown on the Drawings and as specified herein.
1.02 RELATED WORK
A. Concrete formwork is included in Section 03100.
B. Concrete reinforcement is included in Section 03200.
C. Cast-in-place concrete is included in Section 03300.
D. Concrete finishes are included in Section 03350.
E. Grout is included in Section 03600.
F. Modifications to existing concrete are included in Section 03740.
G. Miscellaneous metals are included in Section 05500.
1.03 SUBMITTALS
A. Submit, in accordance with Section 01300, shop drawings and product data for:
1. Plastic Waterstops: Product data including sample, catalogue cut, technical data, storage requirements, splicing methods and conformity to CRD standards.
2. Premolded joint fillers: Product data including location of use, sample, catalogue cut, technical data, storage requirements, installation instructions, and conformity to ASTM standards.
3. Bond breaker: Product data including location of use, catalogue cut, technical data, storage requirements, and application instructions.
4. Expansion joint dowels: Product data on the complete assembly including dowels, coatings, expansion dowel caps, installation instructions and conformity to ASTM standards.
5. Sealant: Product data including location of use, catalogue cut, technical data, storage requirements, mixing and application instructions, and conformity to ASTM standards.
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6. Neoprene bearing pads: Product data including location of use, sample, catalogue cut, technical data, storage requirements, installation instructions, and conformity to AASHTO standards.
B. Certifications
1. Certify that all materials used within the joint system are compatible with each other.
2. Certify that sealant is made for use in continuous immersion in contact with wastewater.
1.04 REFERENCE STANDARDS
A. American Society for Testing and Materials (ASTM)
1. ASTM A36 - Standard Specification for Carbon Structural Steel.
2. ASTM A167 - Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip.
3. ASTM A283 - Standard Specification for Low and Intermediate Tensile Strength Carbon Steel Plates.
4. ASTM A615 – Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement.
5. ASTM A675 - Standard Specification for Steel Bars, Carbon, Hot Wrought, Special Quality, Mechanical Properties.
6. ASTM B127 - Standard Specification for Nickel-Copper Alloy (UNS NO4400) Plate, Sheet and Strip.
7. ASTM C920 - Standard Specification for Elastomeric Joint Sealants.
8. ASTM D1752 - Standard Specification for Preformed Sponge Rubber Cork and Recycled PVC Expansion Joint Fillers for Concrete Paving and Structural Construction.
B. U.S. Army Corps of ENGINEERs (CRD).
1. CRD C572 - Specification for Polyvinylchloride Waterstops.
C. American Association of State Highway and Transportation Officials (AASHTO)
1. Standard Specifications for Highway Bridges
D. Federal Specifications (FS)
1. FS SS-S-210A - Sealing Compound for Expansion Joints.
E. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.
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1.05 QUALITY ASSURANCE
A. Provide services of a Manufacturer’s field representative of the sealant who has performed at least five projects of similar size and complexity within the last 5 years. The field representative shall be present at the work site prior to any mixing of components to instruct on mixing, application and inspection procedures and to inspect the finish of the prepared surfaces prior to application of the sealant.
B. The Manufacturer’s field representative shall make at least one additional visit to the site as the work progresses and shall report on each visit to the Contractor and the Engineer, advising as to whether the application is being performed in accordance with this Section and the Manufacturer’s printed instructions.
1.06 DELIVERY, STORAGE AND HANDLING
A. Deliver products in original, unopened containers displaying the Manufacturer’s label showing Manufacturer name, product identification and batch number.
B. Store products as recommended by the Manufacturer.
PART 2 PRODUCTS
2.01 GENERAL
A. All materials used together in a given joint shall be compatible with one another. Coordinate selection of suppliers and products to provide compatibility. Do not use asphaltic bond breakers or asphaltic joint fillers in joints receiving sealant.
2.02 MATERIALS
A. Plastic Waterstops
1. Waterstops for expansion joints: 9-in by 3/8-in ribbed type waterstops with a center bulb conforming to CRD C572 and made by extruding elastomeric plastic compound with virgin polyvinylchloride as the basic resins. The compound shall contain no reprocessed materials. Minimum tensile strength of waterstop 1750 psi. Waterstops shall be style CR-9380 by Paul Murphy Plastics Co., Roseville, MI; style 696 by Greenstreak Plastic Products, St. Louis, MO; style RLB9-38 by Vinylex Corp., Knoxville, TN, or equal.
2. Waterstops for non-expansion joints and other locations shown on the Drawings: 6-in by 3/8-in ribbed type waterstops conforming to CRD C572 and made by extruding elastomeric plastic compound with virgin polyvinylchloride as the basic resins. The compound shall contain no reprocessed materials. Minimum tensile strength of waterstop 1750 psi. Waterstops shall be style FR-6380 by Paul Murphy Plastics Co., Roseville, MI; style 679 by Greenstreak Plastic Products, St. Louis, MO; style R6-38 by Vinylex Corp., Knoxville, TN, or equal.
3. Waterstops for horizontal construction joints in walls: 4-in by 3/16-in ribbed type waterstops conforming to CRD C572 and made by extruding elastomeric plastic
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compound with virgin polyvinylchloride as the basic resins. The compound shall contain no reprocessed materials. Minimum tensile strength of waterstop 1750 psi. Waterstops shall be style FR-4316 by Paul Murphy Plastics Co., Roseville, MI; style 781 by Greenstreak Plastic Products, St. Louis, MO; style R4-316T by Vinylex Corp., Knoxville, TN, or equal.
B. Premolded Joint Filler
1. Premolded Joint Filler – Structures: Self-expanding cork premolded joint filler conforming to ASTM D1752, Type III. Provide 1-in thickness unless otherwise indicated on the Drawings.
C. Bond Breaker
1. Bond Breaker Tape: Adhesive-backed glazed butyl or polyethylene tape which will adhere to the premolded joint filler or concrete surface. Provide tape the same width as the joint.
2. Bond breaker for concrete other than where tape is indicated on the Drawings or specified: Either bond breaker tape or a non-staining type bond prevention coating such as Crete-Lease Bond Breaker for Tilt-Up by Cresset Chemical Co.; Sure-Lift J-6 WB by Dayton Superior; Silcoseal Select by Nox-Crete, or equal.
D. Compressible Joint Filler
1. A non-extrudable watertight strip material used to fill expansion joints between structures. The material shall be capable of being compressed at least 40 percent for 70 hours at 68 degrees F and subsequently recovering at least 20 percent of its original thickness in the first 1/2 hour after unloading. Compressible joint filler shall be Evazote 380 E.S.P, by E-Poxy Industries, Inc., Ravena, NY or equal.
E. Expansion Joint Dowels
1. Smooth undeformed steel bars conforming to ASTM A615, Grade 60. Provide dowels straight and clean, free of loose flaky rust and loose scale. Dowels may be sheared to length provided deformation from true shape caused by shearing does not exceed 0.04-in on the diameter of the dowel and extends no more than 0.04-in from the end. Coat bars with a bond breaker on the expansion end of the dowel. Provide expansion dowel caps on the expansion end.
2. Expansion Dowel Caps: No. 87 Dowel Caps by Heckmann Building Products, Inc.; Style K-11 Dowel Caps by the Dayton Superior Corporation; Style 3070 Expansion Tube by Meadow Steel Products, Inc., or equal.
F. Sealant
1. Provide sealant for joints in horizontal surfaces conforming to ASTM C920, Type S or M, Grade P or NS, Class 25. Provide sealant for joints in sloping and vertical surfaces conforming to ASTM C920, Type S or M, Grade NS, Class 25. Provide Use T sealant in pedestrian and vehicular traffic areas and Use NT in non-traffic areas.
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2. Provide sealants made for use in continuous immersion in contact with wastewater. Provide gray colored sealants unless otherwise indicated on the Drawings, specified, or approved.
G. Neoprene Bearing Pads: 50 durometer conforming to AASHTO Standard Specifications for Highway Bridges.
PART 3 EXECUTION
3.01 INSTALLATION
A. Waterstops - General
1. Install waterstops for all joints as shown on the Drawings. Provide waterstops continuous around all corners and intersections so that a continuous seal is provided.
2. Provide a minimum number of connections or splices.
3. Secure waterstops in joints before concrete is placed.
4. Install plastic and steel plate waterstops so that half of the width will be embedded on each side of the joint. Provide waterstops completely embedded in void-free concrete.
5. Terminate waterstops 2-in below the exposed top of walls. Plug center bulbs in expansion joint waterstops with foam rubber, 1-in deep, at all points of termination.
B. Plastic Waterstops
1. Make splices by welding in accordance with the Manufacturer’s recommendations. Use only Manufacturer’s special approved tools for welding. The finished splices shall provide a cross-section that is dense and free of porosity. After splice has cooled, spark test all splices in accordance with Manufacturer’s printed instructions. If splice shows any separation or lack of fusion reject the splice, recut back at least 1-in from rejected splice each side, reweld and retest.
2. Secure waterstops in wall joints before concrete is placed. If waterstop does not incorporate an integral fastening system, drill holes in waterstops 1-in from each edge or between the outermost ribs at each edge. Center the waterstop in the joint. Tie both edges of the waterstop to reinforcing steel with tie wire as specified for tying reinforcing steel. Secure the waterstop centered on and perpendicular to the joint and to maintain this position during concrete placement.
3. Space waterstop ties to match the spacing of the adjacent reinforcing, but ties need not be spaced closer than 12-in on center.
4. Clamp horizontal waterstops in slabs in position with the form bulkhead (unless previously set in concrete). Lift the edge of the waterstop while placing concrete below the waterstop. Manually force the waterstop against and into the placed concrete and cover with fresh concrete, to provide complete encasement of the waterstop in concrete.
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C. Construction Joints
1. Make construction joints only at locations shown on the Drawings or as approved by the Engineer. Any additional or relocation of construction joints proposed by the Contractor must be submitted to the Engineer for written approval. Do not eliminate construction joints.
2. Locate additional or relocated joints where they least impair strength of the member. In general, locate joints within the middle third of spans of slabs, beams and girders. However, if a beam intersects a girder at the joint, offset the joint a distance equal to twice the width of the member being connected. Locate joints in walls and columns at the underside of floors, slabs, beams or girders and at tops of footings or floor slabs. Do not locate joints between beams, girders, column capitals, or drop panels and the slabs above them. Do not locate joints between brackets or haunches and walls or columns supporting them.
3. Unless indicated otherwise, provide joints perpendicular to main reinforcement. Continue reinforcing steel through the joint as indicated on the Drawings.
4. At all construction joints and at concrete joints indicated on the Drawings to be "roughened", uniformly roughen the surface of the concrete to a full amplitude (distance between high and low points and side to side) of 1/4-in with chipping tools to expose a fresh face. Thoroughly clean joint surfaces of loose or weakened materials by waterblasting or sandblasting and prepare for bonding. At least two hours before and again shortly before the new concrete is deposited, saturate the joints with water. After glistening water disappears, coat joints with neat cement slurry mixed to the consistency of very heavy paste. The surfaces shall receive a coating at least 1/8-in thick, scrubbed-in by means of stiff bristle brushes. Deposit new concrete before the neat cement dries.
5. Provide waterstops in wall and slab construction joints in liquid retaining structures and at other locations shown on the Drawings.
6. Do not use keyways in construction joints unless specifically shown on the Drawings or approved by the Engineer.
D. Expansion Joints
1. Make expansion joints at locations indicated on the Drawings. Do not eliminate or relocate expansion joints.
2. Do not extend through expansion joints, reinforcement or other embedded metal items that are continuously bonded to concrete on each side of joint.
3. Position premolded joint filler material parallel to finished surfaces. Secure the joint filler against displacement during concrete placement and consolidation. Place joint filler over the face of the joint, allowing for sealant grooves as indicated. Tape all joint filler splices to prevent intrusion of mortar. Seal expansion joints as indicated on the Drawings.
4. Provide expansion joints 1-in in thickness unless otherwise indicated on the Drawings.
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5. Where indicated on the Drawings install smooth dowels at right angles to expansion joints. Align dowels with finished surface. Rigidly hold in place and support during concrete placement. Unless otherwise indicated on the Drawings apply a bond breaker to one end of all dowels through expansion joints. Provide expansion dowel caps on the lubricated ends of expansion dowels.
6. Provide center bulb type waterstops, sealant grooves, and sealants in wall and slab expansion joints in liquid retaining structures and at other locations shown on the Drawings.
E. Control Joints
1. Make control joints at locations shown on the Drawings. Do not eliminate or relocate control joints.
2. Provide waterstops, sealant grooves, and sealants in wall and slab control joints in liquid retaining structures and at other locations shown on the Drawings.
3. Extend every other bar of reinforcing steel through control joints or as indicated on the Drawings. Coat the concrete surface with a bond breaker prior to placing new concrete against it as shown on the Drawings. Do not coat reinforcement or waterstops with bond breaker.
F. Sealant
1. Install sealants in clean dry recesses free of frost, oil, grease, form release agent, loose material, laitance, dirt, dust and other materials which will impair bond at the locations shown on the Drawings. Apply sealant conforming to the Manufacturer’s recommendations including concrete cure, temperature, moisture, mixing, primer, primer cure time, joint and recess preparation, tooling, and curing. Apply masking tape to each side of the joint prior to the installation of the sealant and remove afterwards along with any spillage to leave a sealant installation with neat straight edges.
G. Compressible Joint Filler
1. Install compressible joint filler in conformance with the Manufacturer’s recommendations; including surface preparation, adhesive installation, heat welding and set time.
END OF SECTION
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SECTION 03300
CAST-IN-PLACE CONCRETE
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required to place all cast-in-place concrete, including thrust blocks, concrete encasement of pipes, valve boxes, and items specified under other Sections.
B. All cast-in-place concrete work shall be performed in accordance with ACI 318 except as hereinafter specified.
1.02 RELATED WORK
A. Testing and testing laboratory services are included in Section 01410.
1.03 REFERENCE SPECIFICATIONS
A. American Concrete Institute (ACI)
1. ACI 301 Specifications for Structural Concrete for Buildings.
2. ACI 304 Recommended Practice for Measuring, Mixing, Transporting, and Placing Concrete.
3. ACI 305 Hot Weather Concreting.
4. ACI 306 Cold Weather Concreting.
5. ACI 308 Standard Practice for Curing Concrete.
6. ACI 309 Standard Practice for Consolidation of Concrete.
7. ACI 318 Building Code Requirements for Reinforced Concrete.
8. ACI 347 Recommended Practice for Concrete Formwork.
9. ACI 350 Concrete Sanitary Engineering Structures.
B. American Society for Testing and Materials (ASTM)
1. ASTM C33 Specification for Concrete Aggregates.
2. ASTM C94 Specification for Ready-mix Concrete.
3. ASTM C150 Specification for Portland Cement.
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4. ASTM C260 Specification for Air-Entraining Admixtures for Concrete.
5. ASTM C494 Specification for Chemical Admixtures for Concrete.
C. National Ready-Mixed Concrete Association
1. Truck Mixer and Agitator Standards
1.04 SUBMITTALS
A. Submit to the Engineer for review in accordance with Section 01300 complete shop drawings, working drawings and product data showing placement of forms, form joints, locations of form ties in exposed exterior concrete, and other installations as shown in the Drawings.
B. Submit to the Engineer for review in accordance with Section 01300 the proposed methods of concrete placement, curing, and protection.
C. Submit to the Engineer for review in accordance with Section 01300 the proposed concrete mixes designed within the limits of these specifications, listing the brand and type of cement, source and results of tests of aggregates and admixtures, at least 14 days prior to the beginning of placing concrete.
D. Deliver to the Engineer concrete mix tickets as hereinafter specified.
1.05 QUALITY ASSURANCE
A. The actual acceptance of aggregates and development of mix proportions to produce concrete conforming to the specific requirements shall be determined prior to the placement of any concrete, by means of laboratory tests made with the constituents to be used on the work.
B. The limiting strengths, water-cement ratios and cement factors as shown on Table A shall apply. Maximum water-cement ratio (#/#) for water retaining structures shall be 0.45.
TABLE A
Minimum Maximum Net Minimum Comp. Str. Water Content Cement Factor psi at 28 days gals/100 lbs* 100 lbs/cu yd**
2,500 7.4 4.3 4,000 5.4 5.64
Maximum; decrease if possible. This represents total water in mix at time of mixing, including free water on aggregates, and water in admixture solution.
Minimum; increase as necessary to meet other requirements. These cement factors apply to "controlled" concrete subject to specific inspection.
C. When high-early-strength portland cement is permitted, the same strength requirements shall apply except that the indicated strengths shall be attained at seven (7) days instead of twenty- eight (28) days.
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D. If, during the progress of the work, it is impossible to secure concrete of the required workability and strength with the materials being furnished, the Engineer may order such changes in proportions or materials, or both, as may be necessary to secure the desired properties. All changes so ordered shall be made at the Contractor's expense.
E. If, during the progress of the work, the Contractor desires to use materials other than those originally approved, or if the materials from the sources originally approved change in characteristics, the Contractor shall, at his own expense, have made new acceptance tests of aggregates and establishment of new basic mixtures and submit them to the Engineer for approval.
F. Under special circumstances, the Engineer may allow minor deviations from the material requirements specified, provided the resulting concrete quality is not adversely affected or provided a suitable adjustment in cement content is made to compensate for such deviations without cost to the Owner.
G. Consistency of the concrete as measured by the ASTM Designation C143 shall be as shown in Table B.
TABLE B
Slump (Inches) Portion of Structure Maximum* Minimum
Pavement and slabs on ground 4 2
Plain footings, gravity walls, and slabs 4 2
May be increased 1-inch if proper method of consolidation is used.
H. Concrete shall be of such consistency and mix composition that it can be readily worked into the corners and angles of the forms and around the reinforcement, inserts, and wall castings without permitting materials to segregate or free water to collect on the surface, due consideration being given to the methods of placing and compacting.
I. No excessively wet concrete will be permitted, and if at any time concrete of such consistency beyond the limits of Table B is delivered to the job, the Engineer may direct the Contractor to reject same or to add extra cement for which no additional payment will be made. A supply of the approved cement shall be kept available at the site for this purpose. No additional water shall be added by drivers of transit-mix trucks except that established for the design. Failure to comply with this requirement shall be justification for rejecting the concrete.
J. The entrained air, as measured by the Pressure Method, ASTM C231, shall be 3.0 to 6.0 Percent for all concrete measured at the discharge from the truck.
1.06 ACCEPTANCE TESTS
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A. Conformity of aggregates to these Specifications, and the actual proportions of cement, aggregates, and water necessary to produce concrete conforming to the requirements set forth in Table A, shall be determined by tests made with representative samples of the materials to be used on the work. Tests will be made by an accredited testing laboratory selected by the Contractor and approved by the Engineer in accordance with Section 01410.
B. Cement may be subject to testing to determine that it conforms to the requirements of this Specification. Methods of testing shall conform to the appropriate specification, but the place, time, frequency, and method of sampling will be determined by the Engineer in accordance with the particular need.
C. Samples of fine and coarse aggregates shall be delivered to the laboratory for examination and testing at least three weeks before the Contractor proposes to use them in the work.
PART 2 PRODUCTS
2.01 MATERIALS
A. Concrete shall be of portland cement, fine aggregate, coarse aggregate, water and admixtures as specified and shall be ready-mixed, or transit-mixed concrete produced by a plant acceptable to the Engineers. All constituents, including admixture, shall be batched at the central batch plant in accordance with ASTM C-94. Materials shall conform to these Specifications and any State or local specification requirements.
B. Cement:
1. Cement for all cast in place concrete shall be a domestic portland cement (ASTM C150, Type II) or high early strength portland cement (ASTM C150, Type III) free from injurious water soluble salts or alkalies.
2. High early strength cement may only be used with written approval of the Engineer.
3. Air entraining cements shall not be used.
4. Cement brands shall be subject to approval of the Engineer.
C. Aggregates:
1. Fine aggregate shall consist of washed inert sand conforming to the requirements of ASTM C33, and the following detailed requirements:
Sieve % Passing
No. 4 95-100% 16 60-75 50 13-30 100 3-8
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Fineness Modulus 2.60-3.00 Organics Organic Plate 2, per ASTM C40 Silt 2.0% maximum Mortar Strength 95% minimum as per ASTM C87 Section 10 Soundness 8% maximum loss, using magnesium sulfate, subjected to 5 cycles
2. Coarse aggregate shall consist of well-graded crushed rock or washed gravel conforming to the requirements of ASTM C33 and the following detailed requirements:
Organics Organic Plate 1, per ASTM C40 Silt 1.0% maximum Soundness 8% maximum loss, using magnesium sulfate, subjected to 5 cycles
3. The following designated sizes* of aggregate shall be the maximum employed in concrete:
2-inch for plain concrete 3/4-inch for reinforced sections less than 10-in thickness
4. *Note: The "Designated Size" and the corresponding gradations shown represent the end or combined gradation of the coarse aggregate to be used in the final concrete.
D. Water:
1. Water shall be clean and free from injurious amounts of oils, acid, alkali, organic matter, or other deleterious substances.
2. When subjected to the mortar strength test described in ASTM C87, the 28 day strength of mortar specimens made with the water under examination and normal portland cement shall be at least 100 per cent of the strength of similar specimens made with distilled water.
3. Potable tap water will normally fulfill the above requirements.
E. Admixtures:
1. A water reducing agent such as Pozzolith, WRDA or equal shall be used in all concrete. The admixture shall conform to ASTM C494. Proportioning and mixing shall be as recommended by the manufacturer.
2. Admixtures causing accelerated setting of cement in concrete shall not be used. Air entraining admixtures with demonstrated compatibility with the concrete mix shall be used as required as a moderate addition to the water reducing agent to obtain the specified percent air in the resultant concrete.
F. Grout:
1. Grout for setting bearing plates for structural steel, machinery, and other equipment shall be mixed as recommended by the manufacturer to give the necessary consistency for
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placing and to give a minimum compressive strength of 3,000 lbs per square inch in three (3) days, and 6,800 lbs per square inch in twenty-eight (28) days.
2. Non-shrink grout shall be Masterflow 713 as manufactured by the Master Builders Company, Euco N-S by Euclid Chemical Co., Five Star Grout by U.S. Grout Corp., or equal.
PART 3 EXECUTION
3.01 MEASURING MATERIALS
A. Materials shall be measured by weighing except as otherwise specified or where other methods are specifically authorized by the Engineer. The apparatus provided for weighing the aggregates and cement shall be suitably designed and constructed for this purpose. Scales shall have been certified by the local Sealer of Weights and Measures within one year of use. Each size of aggregate and the cement shall be weighed separately. The accuracy of all weighing devices shall be such that successive quantities can be measured to within one percent of the desired amount. Cement in standard packages (sacks) need not be weighed, but bulk cement and fractional packages shall be weighed.
B. Water shall be measured by volume or by weight. The water-measuring device shall be capable of control to 1/2% accuracy. All measuring devices shall be subject to approval. Admixtures shall be dispensed either manually with use of calibrated containers or measuring tanks, or by means of an approved automatic dispenser designed by the manufacturer of the specific admixture.
3.02 MIXING
A. Concrete shall be ready-mixed, or transit-mixed, as produced by equipment acceptable to the Engineer. No hand-mixing will be permitted. Adding water in controlled amounts during the mixing cycle shall be done only with the express approval of, and under the direction of, the Engineer.
B. Ready-mix or transit-mixed concrete shall be transported to the site in watertight agitator or mixer trucks loaded not in excess of rated capacities for the respective conditions as stated on the name plate. Discharge at the site shall be within 1-1/2 hours and within one hour when ambient temperature is above 85 degree F after cement was first introduced into the mix. Central mixed concrete shall be plant-mixed a minimum of 1-1/2 minutes per batch and then shall be truck-mixed or agitated a minimum of 8 minutes. Agitation shall begin immediately after the pre-mixed concrete is placed in the truck and shall continue without interruption until discharge. Transit-mixed concrete shall be mixed at mixing speed for at least 10 minutes immediately after charging the truck, followed by agitation without interruption until discharged.
C. All central plant and rolling stock equipment and methods shall conform to ACI 304, ASTM C94, and the latest Truck Mixer and Agitator Standards of the Truck Mixer Manufacturers' Bureau of the National Ready-Mixed Concrete Association.
D. The retempering of concrete or mortar which has partially hardened, that is, mixing with or without additional cement, aggregate, or water, will not be permitted.
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E. Attention is called to the importance of dispatching trucks from the batching plant so that they shall arrive at the site of the work just before the concrete is required, thus avoiding excessive mixing of concrete while waiting or delays in placing successive layers of concrete in the forms.
F. Deliver to the Engineer at the time of each truckload transported to the site a mix ticket, showing at least the following: concrete plant identification, date, quantity of ingredients (including water) added at the batch plant, time of charge, and truck number.
3.03 INSPECTION AND CONTROL
A. Batching, mixing, transporting, placing and curing of concrete shall be subject to the inspection of the Engineer at all times. Advise the Engineer of readiness to proceed at least six working hours prior to each concrete placement. The Engineer will inspect the preparations for concreting including the preparation of previously placed concrete, the reinforcing and the alignment, cleanliness and tightness of formwork. Do not place concrete without the inspection and acceptance of the Engineer.
3.04 FIELD TESTS
A. Sets of five field control cylinder specimens shall be taken for every fifty (50) cubic yards of concrete placed. During cold weather concreting, one additional test cylinder shall be taken and cured on the job site under the same conditions as the concrete it represents. Not less than one set of specimens shall be taken on any one day when concrete is being placed. One slump test shall be performed for each set of test cylinders taken and for each concrete mixer truck load delivery. All specimens shall be taken in conformance with ASTM C31. When average ultimate 28-day strength of control cylinders in any set falls below the required ultimate strength or below proportional minimum 7-day strengths where proper relation between 7 and 28-day strengths have been established by tests, proportions, water content, or temperature conditions shall be changed to secure the required strength.
B. The Contractor shall cooperate in the making of such tests to the extent of allowing free access to the work for the selection of samples, providing heated (when required) moist storage facilities for specimens, affording protection to the specimens against injury or loss through his operations, and furnishing material and labor required for the purpose of taking concrete cylinder samples, curing boxes, and shipping boxes.
C. Air entrainment shall be measured by the testing laboratory at time of concrete deposit in accordance with ASTM C231.
3.05 CONCRETE APPEARANCE
A. Concrete for every part of the work shall be of homogeneous structure which, when hardened, will have the required strength, durability and appearance.
B. Formwork, mixtures and concrete placement workmanship shall be such that concrete surfaces, when exposed, will require only minimal finishing with no excess honeycombing, voids or irregular color lines.
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3.06 FORMS
A. Forms shall be used for all concrete masonry, including footings. Forms shall be so constructed and placed that the resulting concrete will be of the shape, lines, dimensions, appearance, and to the elevations indicated on the Drawings.
B. Forms shall be made of wood, metal, or other approved material. Wood forms shall be constructed of sound lumber or plywood of suitable dimensions, free from knotholes and loose knots; where used for exposed surfaces, boards shall be dressed and matched. Plywood shall be sanded smooth and fitted with tight joints between panels. Metal forms shall be of an approved type for the class of work involved and of the thickness and design required for rigid construction. C. Edges of all form panels in contact with concrete shall be flush within 1/32-inch and forms for plane surfaces shall be such that the concrete will be plane within 1/16-inch in 4 feet. Forms shall be tight to prevent the passage of mortar and water and grout.
D. Forms shall be sufficiently rigid to withstand vibration, to prevent displacement or sagging between supports, and constructed so the concrete will not be damaged by their removal. The Contractor shall be entirely responsible for their adequacy.
E. Forms, including new pre-oiled forms, shall be oiled before reinforcement is placed, with an approved nonstaining oil or liquid form coating having a non-paraffin base.
F. Before form material is re-used, all surfaces in contact with concrete shall be thoroughly cleaned, all damaged places repaired, all projecting nails withdrawn, all protrusions smoothed and in the case of wood forms pre-oiled.
G. Form ties encased in concrete shall be designed so that after removal of the projecting part, no metal shall be within 1-inch of the face of the concrete. That part of the tie to be removed shall be at least -inch diameter or be provided with a wood or metal cone at least -inch in diameter and 1-inch long. Form ties in concrete exposed to view shall be the cone-washer type equal to the Richmond "Tyscru". Throughbolts or common wire shall not be used for form ties. Ties for water-holding structures shall have an integral water stop that is tightly welded to the tie.
3.07 PLACING AND COMPACTING
A. Unless otherwise permitted, the work begun on any day shall be completed in daylight of the same day.
B. Concrete is not to be placed until reinforcing steel, pipes, and other work required to be built into concrete have been inspected and approved by the Engineer. Remove water and foreign matter from forms and excavation. Place no concrete on frozen soil, and provide adequate protection against frost action during freezing weather. All soil bottom for slabs and footings shall be approved by the Engineer before placing concrete.
C. Transport concrete from mixer to place of final deposit as rapidly as practicable by methods which prevent separation of ingredients and displacement of reinforcement, and which avoid rehandling. Partially hardened concrete is not to be used.
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D. "Cold joints" are to be avoided, but if they occur, are to be treated as bonded construction joints.
E. At construction joints the surfaces of the concrete already placed, including vertical and inclined surfaces, shall be thoroughly cleaned of foreign materials and laitance, and weak concrete and roughened with suitable tools to expose a fresh face. At least two hours before and again shortly before the new concrete is deposited, the joints shall be saturated with water. After glistening water disappears, the joints shall be given a thorough coating of neat cement slurry mixed to the consistency of very heavy paste. The surfaces shall receive a coating at least 1/8-inch thick, well scrubbed-in by means of stiff bristle brushes whenever possible. New concrete shall be deposited before the neat cement dries.
F. Deposit concrete to maintain, until the completion of the unit, a horizontal plastic surface. Vertical lifts shall not exceed 24-inches and preferably 18-inches.
G. Chutes for conveying concrete shall be of U-shaped design and sized to insure a continuous flow of concrete. Flat (coal) chutes shall not be employed. Chutes shall be metal or metal-lined and each section shall have approximately the same slope. The slope shall not be less than 25 nor more than 45 degrees from the horizontal and shall be such as to prevent the segregation of the ingredients. The discharge end of the chute shall be provided with a baffle plate or spout to prevent segregation. If the discharge end of the chute is more than 5 feet above the surface of the concrete in the forms, a spout shall be used, and the lower end maintained as near the surface of deposit as practicable. When the operation is intermittent, the chute shall discharge into a hopper. Chutes shall be thoroughly cleaned before and after each run, and the debris and any water shall be discharged outside the forms. Concrete shall not be allowed to flow horizontally over distances exceeding 5 feet.
H. The pumping of concrete is an acceptable method. The proposed equipment and concrete mix shall be submitted to the Engineer for review prior to usage. The Contractor shall submit his entire plan of operation from time of discharge of concrete from the mixer to final placement in the forms, and the steps to be taken to prevent the formation of cold joints in case the transporting of concrete by chute, conveyor, or pumps is disrupted.
1. Aluminum alloy pipelines shall not be used for delivery of concrete.
2. The trial mixes intended for pumping shall be prepared and tested in laboratory in accordance with all applicable ASTM Standards, and comply to all above mentioned requirements.
3. The selected trial mixes shall be tested for pumpability. The pumpability test(s) involves a duplication of anticipated job conditions from beginning to end. The batching and truck mixing shall be the same as will be used, the same pump and operator shall be present and the pipe and/or hose layouts shall reflect the maximum height and distance contemplated.
4. If a go-devil device pushed by water is used to clean out the pipe, additional measures to prevent water spillage into the placement area shall be taken.
5. Sampling as indicated by the Engineer at both the truck discharge and points of final placement shall be employed to determine if any changes in the slump, air content and
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other significant mix characteristic occur. However, only the quality of the concrete at the placement end of the line will be considered.
6. No water will be permitted to be added in order to increase workability.
7. Pumps shall be operated and maintained so that a continuous stream of concrete is delivered into the forms without air pockets, segregation, or change in slump. When pumping is completed, concrete to be used remaining in the pipeline shall be ejected without contamination of concrete or segregation of ingredients. After each operation, equipment shall be thoroughly cleaned, and the flushing water shall be wasted outside the forms. Standby equipment shall be provided to assure continuity of operation when clogging or breakdown occur.
I. In thin sections of considerable height, concrete shall be placed using suitable hoppers, spouts with restricted outlets, or otherwise, as required or approved.
J. Concrete during and immediately after depositing shall be thoroughly compacted by means of suitable tools. Internal type mechanical vibrators shall be employed to produce required quality of finish. Vibration shall be done by experienced operators under close supervision and shall be carried on long enough to produce homogeneity and optimum consolidation without permitting segregation of the solid constituents or "pumping" or migration of air. All vibrators shall be supplemented by proper wooden spade puddling adjacent to forms to remove included bubbles and honeycomb. This is essential for the top lifts of walls. All vibrators shall travel at least 10,000 rpm and be of adequate capacity. At least one vibrator shall be used for every 10 cubic yards of concrete placed per hour. In addition, one spare vibrator in operating condition shall be on the site.
K. Concrete slabs on the ground shall be well-tamped into place and foundation material shall be wet, tamped, and rolled until thoroughly compacted prior to placing concrete.
L. Concrete shall be deposited continuously in layers of such thickness that no concrete will be deposited on concrete which has hardened sufficiently to cause the formation of seams and planes of weakness within the section. If a section cannot be placed continuously, construction joints may be located at points as provided for in the Drawings or approved by the Engineer.
3.08 CURING AND PROTECTION
A. Protect all concrete work against injury from the elements and defacements of any nature during construction operations.
B. Concrete placed at air temperature below 40 degrees F shall have a minimum temperature of 60 degrees F. When the air temperature is below 40 degrees F or near 40 degrees F and falling, the water and aggregates shall be heated before mixing. Accelerating chemicals shall not be used to prevent freezing. All concrete shall be so protected that the temperature at the surface will not fall below 50 degrees F for at least 7 days after placing. The Contractor shall submit for approval by the Engineer the methods he proposes to use against low temperatures. No salt, manure, or other chemicals shall be used for protection.
C. All concrete, particularly exposed surfaces, shall be treated immediately after concreting or cement finishing is completed to provide continuous moist curing above 50 degrees F for at
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least 7 days regardless of the ambient air temperature. Walls and vertical surfaces may be covered with continuously saturated burlap, or other approved means; horizontal surfaces, slabs, etc., shall be ponded to a depth of -inch or kept continuously wet by use of sprinklers.
D. In cold weather supplementary continuous warm curing (above 50 degrees F) shall provide a total of 350-day degrees (i.e., 5 days 70 degrees F, etc.) of heat.
E. In hot weather, concrete when deposited shall have a placing temperature which will not cause difficulty from loss of slump, flash set or formation of cold joints. In no case shall the temperature of concrete being placed exceed 90 degrees F.
F. Finished surface and slabs shall be protected from the direct rays of the sun to prevent checking and crazing.
3.09 REMOVAL OF FORMS
A. Except as otherwise specifically authorized by the Engineer, forms shall not be removed before the concrete has cured as specified above in subparagraph 3.08C and the concrete has attained a strength of at least 30 percent of the ultimate strength prescribed by the design, and not before reaching the following number of day-degrees (whichever is the longer):
Forms for Day-degree*
Beams and slabs 500 Walls and vertical surfaces (non-water retaining) 100 Walls and vertical surfaces (water retaining) 150
Day-degree: Total number of days times average daily air temperature at surface of concrete. For example, 5 days at a daily weighted average temperature of 60 degrees F equal 300 day-degrees. Temperatures below 50 degrees F not to be included.
B. Shores shall not be removed until the concrete has attained at least 60% of the specified strength and also sufficient strength to support safely its own weight and the construction live loads upon it, but concrete shall be minimum age of 14 days before such removal.
3.10 FAILURE TO MEET REQUIREMENTS
A. Should the strengths shown by the test specimens made and tested in accordance with the above provisions fall below the values given in Table A, the Engineer shall have the right to require changes in proportions as outlined above to apply to the remainder of the work. Furthermore, the Engineer shall have the right to require additional curing on those portions of the structure represented by the test specimens which failed, the cost of such additional curing to be at the Contractor's expense. In the event that such additional curing does not give the strength required, as evidenced by core and/or load tests, the Engineer shall have the right to require strengthening or replacement of those portions of the structure which fail to develop the required strength. The cost of all such core borings and/or load tests and any strengthening or concrete replacement required because strengths of test specimens are below that specified, shall be entirely at the expense of the Contractor. In such cases of failure to meet strength requirements the Contractor and Engineer shall confer to determine what adjustment, if any, can be made in conformity with Sections 16 and 17 of ASTM C94.
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B. When the tests on control specimens of concrete fall below the required strength, the Engineer will permit check tests for strengths to be made by means of typical cores drilled from the structure in accordance with ASTM C42 and C39. In case of failure of the latter, the Engineer, in addition to other recourses, may require, at the Contractor's expense, load tests on any one of the slabs, beams, piles, caps, and columns in which such concrete was used. Test need not be made until concrete has aged 60 days.
C. Slabs or beams, under load test, shall be loaded with their own weights plus a super-imposed load of 2 times design live load. The load shall be applied uniformly over portion being tested in approved manner, and left in position for 24 hours. The structure shall be considered satisfactory if deflection "D" in feet, at end of 24-hour period does not exceed value:
D equals 0.001(L x L)/t
in which "L" is span in feet, "t" is depth of slab or beam in inches.
D. If deflection exceeds "D" in the above formula, the concrete shall be considered faulty unless within 24 hours after removal of the load, slab or beam under test recovers at least 75% of observed deflection.
3.11 PATCHING AND REPAIRS
A. It is the intent of these Specification to require that forms, mixture of concrete and workmanship shall be such that concrete surfaces, when exposed, will require minimal finishing as specified in Paragraph 3.05 above.
B. As soon as the forms have been stripped and the concrete surfaces exposed, fins and other projections shall be removed, recesses left by the removal of form ties (except where ties are left in place during sandblasting) shall be filled, and surface defects which do not impair structural strength shall be repaired. Clean all exposed concrete surfaces and adjoining work stained by leakage of concrete, to approval of the Engineer.
C. Immediately after removal of forms remove plugs and break off metal ties as required by Paragraph 3.06. Holes are then to be promptly filled upon stripping as follows: Moisten the hole with water, followed by a 1/16-inch brush coat of neat cement slurry mixed to the consistency of a heavy paste. Immediately plug the hole with a 1-1.5 mixture of cement and concrete sand mixed slightly damp to the touch (just short of "balling"). Hammer the grout into the hole until dense, and an excess of paste appears on the surface in the form of a spider web. Trowel smooth with heavy pressure. Avoid burnishing.
D. When patching or repairing exposed surfaces the same source of cement and sand as used in the parent concrete shall be employed. Adjust color if necessary by addition of proper amounts of white cement.
E. Rub lightly with a fine carborundum stone at an age of 1 to 5 days if necessary to bring the surface down with the parent concrete. Exercise care to avoid damaging or staining the virgin skin of the surrounding parent concrete. Wash thoroughly to remove all rubbed matter.
F. Defective concrete and honeycombed areas shall be chipped down reasonably square and at least 1-inch deep to sound concrete by means of hand chisels or pneumatic chipping hammers. Irregular voids or surface stones need not be removed if they are sound, free of laitance, and
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firmly embedded in the parent concrete, subject to Engineer's final inspection. If honeycomb exists around reinforcement, chip to provide a clear space at least 3/8-inch wide all around the steel. For areas less than 1-1/2-inch deep, the patch may be made in the same manner as described above for filling form tie holes, care being exercised to use adequately dry (nontrowelable) mixtures and to avoid sagging. Thicker repairs will require build-up in successive 1-1/2-inch layers on successive days, each layer being applied (with slurry, etc.) as described above. To aid strength and bonding of the multiple layer repairs, the Engineer may order the use of Embeco non-shrink, metallic aggregate by the Master Builders Company, Cleveland, OH or Ironite by Fox Industries, Madison IL. as an additive as follows:
Material Volumes Weights
Cement 1.0 1.0 Embeco 0.15 0.25 Sand 1.5 1.5
G. For very heavy (generally formed) patches; the Engineer may order the addition of pea gravel to the mixture and the proportions modified as follows:
Material Volumes Weights
Cement 1.0 1.0 Embeco 0.2 0.33 Sand 1.0 1.0 Pea Gravel 1.5 1.5
H. In cases where the Embeco is employed in multiple patches and a rusty finish is not desired on the surface, such as exposed faces of walls, etc., the final layer (or at least the final -inch) shall be composed of the 1-1.5 grout without Embeco. After hardening, rub lightly as described above for form tie holes.
3.12 INSTALLATION SCHEDULE
A. Concrete fill and duct encasement shall have a minimum compressive strength at 28 days of 2500 psi.
B. Concrete for thrust blocks and pipe encasement shall have a minimum compressive strength at 28 days of 2500 psi.
3.13 FIELD CONTROL
A. The Contractor shall advise the Engineer of his readiness to proceed at least six working hours prior to each concrete placement. The Engineer will inspect the preparations for concreting including the preparation of previously placed concrete, the reinforcing and the alignment and tightness of formwork. No placement shall be made without the prior approval of the Engineer.
B. The Engineer may have cores taken from any questionable area in the concrete work such as construction joints and other locations as required for determination of concrete quality. The results of tests on such cores shall be the basis for acceptance, rejection or determining the continuation of concrete work.
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C. The Contractor shall cooperate in the obtaining of cores by allowing free access to the work and permitting the use of ladders, scaffolding and such incidental equipment as may be required. The Contractor shall repair all core holes to the satisfaction of the Engineer. The work of cutting and testing the cores will be at the expense of the Owner if cores test satisfactorily and will be at the expense of the Contractor if cores test unsatisfactorily.
3.14 MISCELLANEOUS WORK
A. All bolts, anchors, miscellaneous metals or other sleeves and steel work required to be set in the concrete forms for attachment of masonry, structural, and mechanical equipment shall be set or installed under this Section. The Contractor shall be fully responsible for the setting of such materials in the forms and shall correct all such not installed in a proper location or manner at his own expense.
B. Pipes or conduits for embedment, other than those merely passing through shall not be larger in outside diameter than one-third the thickness of the slab, wall, or beam in which they are embedded, unless indicated on the Drawings, nor shall they be spaced closer than three (3) diameters on center, nor so located as to unduly impair the strength of the construction. The Engineer shall approve the location of all conduits and fixtures.
END OF SECTION
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SECTION 03410
PRECAST CONCRETE STRUCTURES
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall furnish all materials, labor and equipment and construct manholes, as shown on the Drawings and as specified herein.
B. The forms, dimensions, concrete, and construction methods shall be approved by the Engineer in advance of construction.
1.02 RELATED WORK
A. Earthwork is included in Section 02221.
B. Concrete is included in Section 03300.
1.03 SUBMITTALS
A. Submit to the Engineer, as provided in the General Conditions, and Section 01300 shop drawings showing details of construction, reinforcing and joints.
1.04 INSPECTION
A. The quality of all materials, the process of manufacture, and the finished sections shall be subject to inspection and approval by the engineer, or other representatives of the Owner. Such inspection may be made at the place of manufacture, or at the site after delivery, or at both places, and the sections shall be subject to rejection at any time on account of failure to meet any of the Specification requirements; even though sample sections may have been accepted as satisfactory at the place of manufacture. Sections rejected after delivery to the job shall be marked for identification and shall be removed from the job at once. All sections which have been damaged after delivery will be rejected, and if already installed, shall be acceptably repaired, if permitted, or removed and replaced, entirely at the Contractor's expense.
B. At the time of inspection, the sections will be carefully examined for compliance with the ASTM designation specified below and these Specifications, and with the approved manufacturer's drawings. All sections shall be inspected for general appearance, dimension, "scratch-strength", blisters, cracks, roughness, soundness, etc. The surface shall be dense and close-textured.
C. Imperfections may be repaired, subject to the approval of the Engineer, after demonstration by the manufacturer that strong and permanent repairs result. Repairs shall be carefully inspected before final approval. Cement mortar used for repairs shall have a minimum compressive strength of 4,000 psi at the end of 7 days and 5,000 psi at the end of 28 days, when tested in
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3-inch by 6-inch cylinders stored in the standard manner. Epoxy mortar may be utilized for repairs subject to the approval of the Engineer.
PART 2 PRODUCTS
2.01 PRECAST CONCRETE SECTIONS
A. Precast concrete manhole barrel and eccentric top sections shall conform to Specifications for precast Reinforced Concrete Manhole Sections, ASTM Designation C478, except as otherwise specified below. The method of construction shall conform to the detailed Drawings appended to these specifications and the following additional requirements.
1. The minimum wall thickness for the various size barrel sections shall be 8 inches.
2. Barrel sections shall have tongue and groove joints. Joints shall have round rubber gaskets set in specially provided indentations. The round rubber "O"-ring gasket shall conform to ASTM C443 standard specifications.
3. Type II cement shall be used except as otherwise approved.
4. The date of manufacture and the name or trademark of the manufacturer shall be clearly marked on the inside of each precast section. Each section of the manhole must be inspected and stamped by an accredited testing laboratory.
5. Sections shall be cured by an approved method for at least 28 days prior to painting and shall not be shipped until at least 2 days after having being painted.
6. Top sections shall be eccentric except that precast concrete slabs shall be used where cover over the top of the pipe is less than 4 feet for all manholes.
7. Precast concrete slabs over top section, where required, shall be capable of supporting the overburden plus a live load equivalent to AASHTO H-20 loading.
8. The tops of bases shall be suitably shaped to mate with the precast barrel section.
9. The exterior and interior of the manhole shall be coated in accordance with Section 09902.
B. Precast electrical handholes and covers shall be as specified and as shown on the Drawings.
C. Precast leveling rings for setting cast iron frames over manholes shall be as shown on the Drawings.
PART 3 EXECUTION
3.01 INSTALLATION
A. Manholes and other precast structures shall be constructed to the dimensions as shown on the Drawings and as specified in these Specifications.
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B. The base shall be cast-in-place concrete as specified in Division 3 placed on bedding rock as specified in Section 02230. The tops of the cast-in-place bases shall be shaped to mate with the precast barrel section, and shall be adjusted in grade so that the top of the dome section is at the approximately correct elevation.
C. Pre-cast bases, conforming to all requirements of ASTM C478 and above listed requirements for precast sections, may be used.
D. Precast concrete structure sections shall be set so as to be vertical and with sections in true alignment with a 1/4-inch maximum tolerance to be allowed. The outside and inside joint shall be filled with a comparatively dry mortar (one part cement to two parts sand) and finished flush with the adjoining surfaces. Allow joints to set for 24 hours before backfilling. Backfilling shall be done in a careful manner, bringing the fill up evenly on all sides. If leaks appear in the structures, the inside joints shall be caulked with lead wool to the satisfaction of the Engineer. The Contractor shall install the precast sections in a manner that will result in a watertight joint.
E. Holes in the concrete with rubber "O" ring gasket sections required for handling or other purposes shall be plugged with a non-shrinking grout or by grout in combination with concrete plugs.
F. Where holes may be cut in the precast sections to accommodate pipes, cutting shall be done prior to setting them in place to prevent any subsequent jarring which may loose the mortar joints.
G. Cast iron frames specified and furnished under Division 5 shall be placed over precast concrete leveling rings, shimmed and set in portland cement mortar to the required grade. No more than three courses of leveling rings shall be used.
END OF SECTION
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SECTION 03600
GROUT
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required and install grout complete as shown on the Drawings and as specified herein.
B. Perform all sampling and furnish all testing of materials and products by an independent testing laboratory acceptable to the Engineer but engaged by and at the expense of the Contractor.
1.02 RELATED WORK
A. Concrete formwork is included in Section 03100.
B. Concrete reinforcement is included in Section 03200.
C. Concrete joints and joint accessories are included in Section 03250.
D. Cast-in-place concrete is included in Section 03300.
E. Precast, prestressed concrete is included in Section 03420.
F. Modifications to existing concrete are included in Section 03740.
G. Masonry grout is included in Section 04200.
H. Structural steel is included in Section 05120.
I. Miscellaneous metals are included in Section 05500.
1.03 SUBMITTALS
A. Submit, in accordance with Section 01300, shop drawings and product data showing materials of construction and details of surface preparation, mixing and installation for:
1. Commercially manufactured non-shrink cementitious grout and self-leveling cementitious underlayment grout. Include catalog cuts, technical data, storage requirements, product life, working time after mixing, temperature considerations, conformity to the specified ASTM standards, and Material Safety Data Sheet.
2. Commercially manufactured non-shrink epoxy grout. Include catalog cuts, technical data, storage requirements, product life, working time after mixing, temperature considerations, conformity to the specified ASTM standards, and Material Safety Data Sheet.
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3. Cement grout. Include the type and brand of cement, the gradation of fine aggregate, product data on any proposed admixtures and the proposed grout mix.
4. Concrete grout. Include data as required for concrete as delineated in Section 03300 and for fiber reinforcement as delineated in Section 03200.
B. Samples
1. Submit samples of commercially manufactured grout products when requested by the Engineer.
2. Submit samples of aggregates proposed for use in grout mixes when requested by the Engineer.
C. Laboratory Test Reports
1. For concrete grout, submit laboratory test data as required for concrete as delineated in Section 03300.
D. Certifications
1. Certify that commercially manufactured grout products and admixtures for cement grout.
2. Certify that the Contractor is not associated with the independent testing laboratory, nor does the Contractor or its officers have a beneficial interest in the laboratory.
E. Qualifications
1. Submit documentation that grout Manufacturers have a minimum of at least 10 years experience in the production and use of the grouts proposed.
2. Independent Testing Laboratory
a. Name and address
b. Names and positions of principal officers and the name, position, and qualifications of the responsible registered professional Engineer in charge.
c. Listing of technical services to be provided. Indicate external technical services to be provided by other organizations.
d. Names and qualifications of the supervising laboratory technicians.
e. Statement of conformance provided by evaluation authority defined in ASTM C1077. Provide report prepared by evaluation authority when requested by the Engineer.
f. Submit as required above for other organizations that will provide external technical services.
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1.04 REFERENCE STANDARDS
A. American Society for Testing and Materials (ASTM)
1. ASTM C33 - Standard Specification for Concrete Aggregates
2. ASTM C150 - Standard Specification for Portland Cement
3. ASTM C531 - Standard Test Method for Linear Shrinkage and Coefficient of Thermal Expansion of Chemical-Resistant Mortars, Grouts and Monolithic Surfacings and Polymer Concretes
4. ASTM C579 - Standard Test Methods for Compressive Strength of Chemical-Resistant Mortars, Grouts, Monolithic Surfacings and Polymer Concretes
5. ASTM C827 - Standard Test Method for Change in Height at Early Ages of Cylindrical Specimens of Cementitious Mixtures
6. ASTM C1077 - Standard Practice for Laboratories Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Laboratory Evaluation
7. ASTM C1107 - Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Non-shrink)
8. ASTM D695 - Standard Test Method for Compressive Properties of Rigid Plastics.
9. ASTM E329 - Standard specification for agencies engaged in the testing and/or inspection of materials used in construction
B. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.
1.05 QUALITY ASSURANCE
A. Qualifications
1. Grout Manufacturers shall have a minimum of 10 years experience in the production and use of the type of grout proposed.
2. Independent testing laboratory shall meet the requirements of ASTM E329 and ASTM C1077 and be acceptable to the Engineer. Laboratories affiliated with the Contractor or in which the Contractor or officers of the Contractor’s organization have beneficial interest are not acceptable.
B. Pre-installation Meeting
1. At least ten working days before grouting, hold a pre-installation meeting to review the requirements for surface preparation, mixing, placing and curing procedures for each product proposed for use. Notify all parties involved with grouting, including the ENGINEER, of the meeting at least ten working days prior to its scheduled date.
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C. Services of Manufacturer’s Representative
1. Provide services of a field technician of the non-shrink grout Manufacturer and of the self-leveling cementitious underlayment grout Manufacturer who has performed at least five projects of similar size and complexity during the last five years, to attend the pre-installation meeting, to be present for the initial installation of each type of non- shrink grout and self-leveling cementitious underlayment grout, and to correct installation problems.
D. Field Testing
1. All field testing and inspection services will be provided by the Owner. Assist in the sampling of materials, and cooperate by allowing free access to the work and permitting the use of ladders, scaffolding, and such incidental equipment as may be required. Methods of testing will comply with the applicable ASTM Standards.
2. Field testing of concrete grout will be as specified for concrete in Section 03300.
1.06 DELIVERY, STORAGE AND HANDLING
A. Deliver materials to the jobsite in original, unopened packages, clearly labeled with the Manufacturer’s name, product identification, batch numbers and printed instructions.
B. Store materials in full compliance with the manufacturer’s recommendations. Limit total storage time from date of manufacture to date of installation to six months or the Manufacturer’s recommended storage time, whichever is less.
C. Remove immediately from the site material which becomes damp, contains lumps, or is hardened and replace with acceptable material at no additional cost to the Owner.
D. Deliver non-shrink cementitious grout and self-leveling cementitious underlayment grout as a pre-portioned blend in prepackaged mixes requiring only the addition of water.
E. Deliver non-shrink epoxy grout as a pre-proportioned, prepackaged, three component system requiring only mixing as directed by the Manufacturer.
1.07 DEFINITIONS
A. Non-shrink Grout: A commercially manufactured product that does not shrink in either the plastic or hardened state, is dimensionally stable in the hardened state and bonds to a clean base plate.
B. Self-Leveling Cementitious Underlayment Grout: A commercially manufactured Portland cement based, non-shrinking, self-leveling underlayment.
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PART 2 PRODUCTS
2.01 GENERAL
A. The use of a Manufacturer’s name and product or catalog number is for the purpose of establishing the standard of quality desired.
B. Like materials shall be the products of one Manufacturer or supplier in order to provide standardization of appearance.
2.02 MATERIALS
A. Non-shrink Cementitious Grout
1. Non-shrink cementitious grouts: Conform to ASTM C1107. Grouts shall be portland cement based, contain a pre-proportioned blend of selected aggregates and shrinkage compensating agents and require only the addition of water. Non-shrink cementitious grouts shall not contain expansive cement or metallic particles. The grouts shall exhibit no shrinkage when tested in conformity with ASTM C827.
a. General purpose non-shrink cementitious grout: Conform to the standards stated above. SikaGrout 212 by Sika Corp.; Set Grout by BASF Building Systems; NS Grout by The Euclid Chemical Co.; Five Star Grout by Five Star Products, Inc., or equal.
b. Flowable (Precision) non-shrink cementitious grout: Conform to the standards stated above. Masterflow 928 by BASF Building Systems; Hi-Flow Grout by The Euclid Chemical Co.; SikaGrout 212 by Sika Corp.; Five Star Grout by Five Star Products, Inc., or equal.
B. Non-shrink Epoxy Grout
1. Non-shrink epoxy grout: Grout shall be pre-proportioned, prepackaged, three component, 100 percent solids system consisting of epoxy resin, hardener and blended aggregate. It shall have a compressive strength of 10,000 psi in 7 days when tested in conformity with ASTM C579 and have a maximum coefficient of thermal expansion of 30 x 10-6 in/in/degrees F when tested in conformity with ASTM C531. Masterflow 648 CP by BASF Building Systems; Five Star HP Epoxy Grout by Five Stars Products, Inc; Sikadur 42 Grout-Pak by Sika Corp.; E3-G Epoxy Grout by the Euclid Chemical Co. or equal.
C. Cement Grout
1. A mixture of one part portland cement conforming to ASTM C150, Type I, II, or III and one to two parts sand conforming to ASTM C33 with sufficient water to place the grout. The water content shall be sufficient to impart workability to the grout but not to the degree that it will allow the grout to flow.
D. Concrete Grout
1. Conform to the requirements of Section 03300 except as specified herein. Proportion with Type II cement, coarse and fine aggregates, water, water reducing admixture and air
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entraining agent to produce a mix having an average strength of 3500 psi at 28 days (2500 psi nominal strength). Coarse aggregate size shall be 1/2-in maximum. Slump shall not exceed 5-in. Minimum cement content shall be 540 lbs per cubic yard and maximum water to cement ratio shall be 0.45.
2. Add synthetic reinforcing fibers as specified in Section 03200 to the concrete grout mix at the rate of 1.5 lbs of fibers per cubic yard of grout. Add fibers from the Manufacturer’s pre-measured bags and according to the Manufacturer’s recommendations to ensure complete dispersion of the fiber bundles as single monofilaments within the concrete grout.
E. Self-Leveling Cementitious Underlayment Grout
1. Grout shall be Portland cement based, non-shrinking, self-leveling underlayment factory prepared and packaged. Underlayment Self-Leveling by BASF Building Systems, LeveLayer by Dayton Superior, Flo-Top by the Euclid Chemical Company, or equal providing a one day compressive strength of 1200 psi minimum and a 28 day value of 3000 psi minimum.
2. Provide polymer emulsion, system primer for substrate preparation, Thoro Underlayment Primer 800 or equal for the specific product proposed.
3. Provide clean, dry and sound pea gravel, ¼-in maximum and 1/8-in minimum size and conforming to ASTM C33 (Provide 1/8-in maximum size, clean, dry and sound sand conforming to ASTM C33 for the equal specific products).
F. Water
1. Potable water free of oil, acid, alkali, salts, chlorides (except those attributable to drinking water), organic matter, or other deleterious substances.
PART 3 EXECUTION
3.01 PREPARATION
A. Place grout where indicated or specified over existing concrete and cured concrete which has attained its specified design strength unless otherwise approved by the Engineer.
B. Concrete surfaces to receive grout shall be clean and sound; free of ice, frost, dirt, dust, grease, oil, form release agent, laitance and paints and free of all loose material or foreign matter which may affect the bond or performance of the grout.
C. Roughen concrete surfaces by chipping, sandblasting, or other dry mechanical means to bond the grout to the concrete. Remove loose or broken concrete. Irregular voids or projecting coarse aggregate need not be removed if they are sound, free of laitance and firmly embedded into the parent concrete.
1. Air compressors used to clean surfaces in contact with grout shall be the oilless type or equipped with an oil trap in the airline to prevent oil from being blown onto the surface.
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D. Remove all loose rust, oil or other deleterious substances which may affect the bond or performance of the grout from metal embedments or bottom of baseplates prior to the installation of the grout.
E. Wash concrete surfaces clean and then keep moist for at least 24 hours prior to the placement of non-shrink cementitious or cement grout. Saturation may be achieved by covering the concrete with saturated burlap bags, use of a soaker hose, or flooding the surface or other method acceptable to the Engineer. Upon completion of the 24 hour period, remove visible water from the surface prior to grouting.
F. Non-shrink epoxy grouts do not require saturation of the concrete substrate. Do not wet concrete surfaces to receive non-shrink epoxy grout. Surfaces in contact with epoxy grout shall be completely dry before grouting.
G. Provide forms for grout. Line or coat forms with release agents recommended by the grout Manufacturer. Provide forms anchored in place and shored to resist the forces imposed by the grout and its placement.
1. Forms for all grout other than concrete grout shall be designed to allow the formation of a hydraulic head and shall have chamfer strips built into forms.
H. Level and align the structural or equipment bearing plates in accordance with the structural requirements or the recommendations of the equipment Manufacturer, as applicable.
1. Support equipment during alignment and installation of grout by shims, wedges, blocks or other approved means. The shims, wedges and blocking devices shall be prevented from bonding to the grout by bond breaking coatings and removed after grouting unless otherwise approved by the Engineer. Grout voids created by the removal of shims, wedges and blocks.
3.02 INSTALLATION - GENERAL
A. Mix, apply and cure products in strict compliance with the manufacturer’s recommendations and these specifications.
B. Provide staffing and equipment available for rapid and continuous mixing and placing. Keep all necessary tools and materials ready and close at hand.
C. Maintain temperatures of the base plate, supporting concrete, and grout between 40 and 90 degrees F during grouting and for at least 24 hours after placement, until grout compressive strength reaches 1000 psi or as recommended by the grout Manufacturer, whichever is longer. Do not allow differential heating or cooling of baseplates and grout during the curing period.
D. Take special precautions for hot weather or cold weather grouting as recommended by the Manufacturer when ambient temperatures and/or the temperature of the materials in contact with the grout are outside of the 40 to 90 degrees F range.
E. Install grout to preserve the isolation between the elements on either side of the joint where grout is placed in the vicinity of an expansion or control joint.
F. Reflect all existing underlying expansion, control and construction joints through the grout.
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3.03 INSTALLATION - NON-SHRINK CEMENTITIOUS GROUTS AND CEMENT GROUTS
A. Mix in accordance with Manufacturer’s recommendations. Do not add cement, sand, pea gravel or admixtures without prior approval by the Engineer.
B. Do not mix by hand. Mix in a mortar mixer with moving blades. Pre-wet the mixer and empty excess water. Add pre-measured amount of water for mixing, followed by the grout. Begin with the minimum amount of water recommended by the Manufacturer and then add the minimum additional water required to obtain workability. Do not exceed the Manufacturer’s maximum recommended water content.
C. Placements greater than 3-in in depth shall include the addition of clean, washed pea gravel to the grout mix when approved by the Manufacturer. Comply with the Manufacturer’s recommendations for the size and amount of aggregate to be added.
D. Provide forms as specified in Paragraph 3.01G. Place grout into the designated areas and prevent segregation and entrapment of air. Do not vibrate grout to release air or to consolidate the material. Fill all spaces and provide full contact between the grout and adjoining surfaces. Provide grout holes and vent holes as necessary.
E. Place grout rapidly and continuously to avoid cold joints. Do not place grout in layers. Do not add additional water to the mix (retemper) after initial stiffening.
F. Just before the grout reaches its final set, cut back the grout to the substrate at a 45 degree angle from the lower edge of bearing plate unless otherwise ordered and approved by the ENGINEER. Finish this surface with a wood float or brush finish.
G. Begin curing immediately after form removal, cutback, and finishing. Keep grout moist and within its recommended placement temperature range for at least 24 hours after placement, until grout compressive strength reaches 1000 psi or as recommended by the MANUFACTURER, whichever is longer. Saturate the grout surface by use of saturated burlap bags, soaker hoses or ponding. Provide sunshades. If drying winds inhibit the ability of a given curing method to keep grout moist, erect wind breaks until wind is no longer a problem or curing is finished.
3.04 INSTALLATION – NON-SHRINK EPOXY GROUTS
A. Mix in accordance with Manufacturer’s recommendations. Mix full batches only, to maintain proper proportions of resin, hardener and aggregate. Do not vary the ratio of components or add solvent to change the consistency of the grout mix. Do not overmix. Do not entrain air bubbles by mixing too quickly.
B. Monitor ambient weather conditions and contact the grout Manufacturer for special placement procedures to be used for temperatures below 60 or above 90 degrees F.
C. Place grout rapidly and continuously to avoid cold joints. Place grout in lifts in accordance with Manufacturer’s recommendations.
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D. Provide forms as specified in Paragraph 3.01G. Place grout into the designated areas and prevent entrapment of air. Fill all spaces and provide full contact between the grout and adjoining surfaces. Provide grout holes and vent holes as necessary.
E. Minimize "shoulder" length (extension of grout horizontally beyond base plate). In no case shall the shoulder length of the grout be greater than the grout thickness.
F. Finish grout by puddling to cover all aggregate and provide a smooth finish. Break bubbles and smooth the top surface of the grout in conformity with the Manufacturer’s recommendations.
G. Epoxy grouts are self curing and do not require the application of water. Maintain the formed grout within its recommended placement temperature range for at least 24 hours after placement, until grout compressive strength reaches 1000 psi or as recommended by the Manufacturer, whichever is longer.
H. Provide grout control joints as indicated on the Drawings.
3.05 INSTALLATION - CONCRETE GROUT
A. Inspect slabs finished under Section 03350 and scheduled to receive concrete grout. Scarify existing slab surfaces to receive concrete grout. Protect and keep the surface clean until placement of concrete grout.
B. Remove debris and clean the surface by sweeping and vacuuming of all dirt and other foreign materials. Pressure wash the surface. Do not flush debris into tank drain lines.
C. Saturate the concrete surface for at least 24 hours prior to placement of the concrete grout by use of saturated burlap bags, soaker hoses or ponding. Remove excess water just prior to placement of the concrete grout. Place a cement slurry immediately ahead of the concrete grout so that the slurry is moist when the grout is placed. Work the slurry over the surface with a broom until it is coated with approximately 1/16 to 1/8-in thick cement paste.
D. Place concrete grout to final grade using the scrapers of the installed mechanical equipment as a guide for surface elevation and to eliminate high and low spots. Unless specifically approved by the equipment Manufacturer, mechanical scraper mechanisms powered by their motors shall not be used as a finishing machine or screed to push grout.
E. Steel trowel finish as specified in Section 03350. Cure the concrete grout as specified for cast- in-place concrete in Section 03300.
3.06 INSTALLATION – SELF-LEVELING CEMETITIOUS UNDERLAYMENT GROUT
A. Perform work generally as follows but conform to installation procedures as submitted and approved.
B. Removal of flooring and underlying fill concrete material are included under Division 2. Provide additional substrate preparation as required to ensure proper bond of the grout system.
C. Prime the prepared substrate with the system primer and remove all puddles. Allow to dry completely.
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D. Mix underlayment grout with water and the approved aggregate only and in the approved proportions to be flowable and self-leveling.
E. Install in one lift for all locations and allow to level. Completely fill the required areas allowing no voids in the grout thickness. Slope to floor drains as required.
F. Cure in conformance with Manufacturer’s instructions. Do not allow conditions which would permit premature drying.
G. Protect the grouted areas as approved until finish material is applied under Division 9.
3.07 SCHEDULE
A. The following list indicates where the particular types of grout are to be used:
1. General purpose non-shrink cementitious grout: Use at all locations where non-shrink grout is indicated on the Drawings, except for base plates greater in area than 3-ft wide by 3-ft long.
2. Flowable (precision) non-shrink cementitious grout: Use under all base plates greater in area than 3-ft wide by 3-ft long. Use at all locations indicated on the Drawings to receive flowable non-shrink grout. Flowable (precision), non-shrink, cementitious grout may be substituted for general purpose non-shrink cementitious grout.
3. Non-shrink epoxy grout: Use at all locations specifically indicated on the Drawings to receive non-shrink epoxy grout.
4. Cement grout: Use where indicated on the Drawings.
5. Concrete grout: Use for overlaying the base concrete under scraper mechanisms of clarifiers, in screw pump troughs, as indicated on the Drawings. Use for concrete grout fill within liquid retaining structures and other locations where specifically indicated on the Drawings.
6. Self-Leveling cementitious underlayment grout: Use over existing slab, as shown and required to provide substrate for tile work.
END OF SECTION
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SECTION 05500
MISCELLANEOUS METAL
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required and install all miscellaneous metal complete as shown on the Drawings and as specified herein.
1.02 RELATED WORK
A. Concrete joint accessories are included in Section 03250.
B. Masonry reinforcement, ties and accessories are included in Division 4.
C. Structural steel, steel joists and steel roof deck are included in Division 5.
D. Metal doors and frames are included in Section 08120.
E. Painting is included in Division 9.
F. Louvers are included in Division 10.
G. Monorail track is included in Division 14.
H. Pipe hangers and sleeves are included in Division 15.
I. Equipment anchor bolts are included in the respective Sections of Divisions 11, 14 and 15.
1.03 SUBMITTALS
A. Submit, in accordance with Section 01300, shop drawings and product data showing materials of construction and details of installation for:
1. Shop drawings, showing sizes of members, method of assembly, anchorage and connection to other members.
B. Samples
1. Submit samples if requested by the Engineer during the course of construction.
C. Design Data
1. Submit calculations or test data demonstrating that the railings will resist the loads specified in the Florida Building Code at the post spacing provided.
2. Submit Manufacturer’s load and deflection tables for grating.
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D. Test Reports
1. Certified copy of mill test reports on each steel, stainless steel, aluminum, proposed for use showing the physical properties and chemical analysis.
E. Certificates
1. Submit certification that the railing system is in compliance with OSHA requirements and the Florida Building Code.
2. Certify that welders have been qualified under AWS, within the previous 12 months, to perform the welds required under this Section.
1.04 REFERENCE STANDARDS
A. Aluminum Association (AA)
1. AA M31C22A41
a. M31: Mechanical Finish, Fine Satin
b. C22: Finish, Medium Matte
c. A41: Clear Anodic Coating, Class I
B. American Society for Testing and Materials (ASTM)
1. ASTM A36 - Standard Specification for Carbon Structural Steel.
2. ASTM A48 - Standard Specification for Gray Iron Castings.
3. ASTM A53 - Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless.
4. ASTM A108 - Standard Specification for Steel Bars, Carbon, Cold Finished, Standard Quality.
5. ASTM A123 - Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products.
6. ASTM A153 - Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware.
7. ASTM A240 - Standard Specification for Heat-Resisting Chromium and Chromium- Nickel Stainless Plate, Sheet, and Strip Pressure Vessels.
8. ASTM A276 - Standard Specification for Stainless Steel Bars and Shapes.
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9. ASTM A307 - Standard Specification for Carbon Steel Bolts and Studs, 60,000 Psi Tensile Strength.
10. ASTM A325 - Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength.
11. ASTM A500 - Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes.
12. ASTM A501 - Standard Specification for Hot-Formed Welded and Seamless Carbon Steel Structural Tubing.
13. ASTM A536 - Standard Specification for Ductile Iron Castings.
14. ASTM A570 - Standard Specification for Steel, Sheet and Strip, Carbon, Hot-Rolled, Structural Quality.
15. ASTM A1008 - Standard Specification for Steel, Sheet, Cold-Rolled, Carbon, Structural, High-Strength Low-Alloy, High-Strength Low-Alloy with Improved Formability, Solution Hardened, and Bake Hardenable.
16. ASTM B209 - Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate.
17. ASTM B221 - Standard Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles and Tubes.
18. ASTM B429 - Standard Specification for Aluminum-Alloy Extruded Structural Pipe and Tube.
C. American Iron and Steel Institute (AISI).
1. Specification for Structural Steel Buildings.
D. American Welding Society (AWS)
1. AWS D1.1 - Structural Welding Code - Steel.
2. AWS D1.2 - Structural Welding Code - Aluminum.
3. AWS D1.6 - Structural Welding Code - Stainless Steel
E. Federal Specifications
1. FS-FF-B-575C - Bolts, Hexagonal and Square
F. Occupational Safety and Health Administration (OSHA)
G. Florida Building Code
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H. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.
1.05 QUALITY ASSURANCE
A. The work of this Section shall be completely coordinated with the work of other Sections. Verify, at the site, both the dimensions and work of other trades adjoining items of work in this Section before fabrication and installation of items herein specified.
B. Furnish to the pertinent trades all items included under this Section that are to be built into the work of other Sections.
C. All welding shall be performed by qualified welders and shall conform to the applicable AWS welding code. Welding of steel shall conform to AWS D1.1 and welding of aluminum shall conform to AWS D1.2 and welding of stainless steel shall conform to AWS D1.6.
1.06 DELIVERY, STORAGE AND HANDLING
A. Deliver items to be incorporated into the work of other trades in sufficient time to be checked prior to installation.
B. Repair items that have become damage or corroded to the satisfaction of the Engineer prior to incorporating them into the work.
1.07 PROJECT/SITE REQUIREMENTS
A. Field measurements shall be taken at the site, prior to fabrication of items, to verify or supplement indicated dimensions and to ensure proper fitting of all items.
PART 2 PRODUCTS
2.01 GENERAL
A. The use of Manufacturer’s name and model or catalog number is for the purpose of establishing the standard of quality and general configuration desired.
B. Like items of materials shall be the end products of one Manufacturer in order to provide standardization for appearance, maintenance and Manufacturer’s service.
2.02 MATERIALS
A. Unless otherwise noted, materials for miscellaneous metals shall conform to the following standards:
1. Structural Steel ASTM A36
2. Structural Steel Tubing ASTM A500, Grade B
3. Welded and Seamless Steel Pipe ASTM A501 or ASTM A53, Type E or S, Grade B Schedule 40. Use standard
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malleable iron fittings, galvanized for exterior work
4. Steel Sheets ASTM A1008
5. Gray Iron Castings ASTM A48, Class 35
6. Ductile Iron Castings ASTM A536, Grade 65-45-12
7. Aluminum Extruded Pipe ASTM B429, Alloy 6063 T6
8. Aluminum Extruded Shapes ASTM B221, Alloy 6061 T6
9. Aluminum Sheet and Plate ASTM B209, Alloy 6061 T6
10. Stainless Steel Plates, Sheets, and Structural Shapes
a. Exterior, Submerged or Industrial Use ASTM A240, Type 316 (Type 316L for welded)
b. Interior and Architectural Use ASTM A240, Type 304
11. Stainless Steel Bolts, Nuts, and Washers ASTM A276, Type 316
12. Carbon Steel Bolts and Studs ASTM A307, Grade A (hot dip galvanized nuts and washers where noted)
13. High Strength Steel Bolts, Nuts and washers ASTM A325 (mechanically galvanized per ASTM B695, Class 50, where noted)
a. Elevated Temperature Exposure Type I
b. General Application Type I or Type II
14. Galvanizing ASTM A123, Zn w/0.05 percent minimum Ni
15. Galvanizing, hardware ASTM A153, Zn w/0.05 percent minimum Ni
2.03 ANCHORS, BOLTS AND FASTENING DEVICES
A. Anchor bolt material shall be ASTM A307 unless otherwise noted.
B. Unless otherwise noted, bolts for the connection of carbon steel or iron shall be steel machine bolts; bolts for the connection of galvanized steel or iron shall be galvanized steel or stainless steel machine bolts; and bolts for the connection of aluminum or stainless steel shall be stainless steel machine bolts.
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C. Adhesive capsule anchors shall be a two-part stud and capsule chemical resin anchoring system. Capsules shall contain premeasured amounts of polyester or vinyl ester resin, aggregate and a hardener contained in a separate vial within the capsule. Stud assemblies shall consist of an all-thread anchor rod with nut and washer. Adhesive capsule anchors shall be HITRE 500-SD Epoxy Adhesive Anchoring System; Molly, Parabond; Rawlplug, Rawl Chem-Stud or equal.
D. Adhesive anchors, for fastening to hollow concrete block or brick, shall be a three-part stud, screen and chemical dispenser anchoring system. Adhesive cartridges shall contain premeasured amounts of resin and hardener which are mixed and deposited in a screen tube by a dispenser. Stud assemblies shall consist of an all-thread anchor rod with nut and washer. Anchors shall be Hilti, HIT HY-20 System or equal.
E. Automatic end welded headed anchor studs shall be flux ended studs made from cold drawn steel, ASTM A108 Grades C-1010 through C-1020. Headed anchor studs shall be Nelson, H4L Headed Concrete Anchors; Nelson, S3L Shear Connectors or equal.
F. Machine bolts and nuts shall conform to Federal Specification FF-B-575C. Bolts and nuts shall be hexagon type. Bolts, nuts, screws, washers and related appurtenances shall be Type 316 stainless steel.
G. Toggle bolts shall be Hilti, Toggler Bolt or equal.
2.04 METAL GRATING
A. Grating shall have rectangular, 3/16-in thick, bearing bars spaced 1-3/16-in on center with cross bars spaced at 4-in on center. All grating panels shall be banded with a bar the same size as the bearing bars.
1. Grating shall be of the same depth shown on the Drawings, not exceed the fabricator's maximum recommended span, and meet or exceed the following load and deflection criteria for the maximum span length at the opening being covered by the grating.
a. The grating shall produce a deflection of 1/360 of the span or less under a uniform live load of 100 lbs/sq ft on the maximum span.
b. The grating shall produce a deflection of 1/360 of the span or less under a concentrated live load of 300 lbs applied at the mid point of the maximum span.
2. Openings 2-in or greater in diameter/dimension and grating edges shall be banded with a bar of the same depth and thickness as the bearing bars. Cut bearing bars or cross bars shall be welded to the banding bar.
3. Provide trench grating with symmetrical cross bar arrangement.
4. Grating clamps, nuts, bolts, washers and other fastening devices for grating and grating supports shall be Type 316 stainless steel. All grating shall be anchored to the supporting system using saddle clips.
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B. Aluminum grating material shall be aluminum alloy 6063-T6 with a mill finish. Cross bars shall be attached to the bearing bars with interlocked swaged joints. The grating shall be Type BS by IKG Borden, Houston, TX; Type 19 SG-4 by Ohio Gratings, Inc., Canton, OH; Type 19S4 by Seidelhuber Metal Products, San Carlos, CA or equal.
C. Steel grating material shall conform to ASTM A570, Grade 36 or ASTM A36, galvanized. Cross bars shall be attached to the bearing bars by welding or with interlocked swaged joints. Grating with cross bars pressed into notches in the top of the bearing bars will not be acceptable. Grating shall be hot-dipped galvanized finish complying with the requirements of ASTM A123, however, the average minimum weight of the zinc coating shall not be less than 2 oz/sq ft.
D. Metal frames and supports for grating shall be of the same material as the grating unless otherwise shown on the Drawings. Where aluminum supports are used, they shall be fabricated from aluminum alloy 6061-T6.
2.05 RAILINGS
A. Handrail and railing systems shall comply with the requirements of OSHA and the Florida Building Code.
B. Aluminum railing and handrail shall be a welded or mechanically fastened, seamless, extruded aluminum pipe system. Rails shall be 6063-T6 alloy. Posts shall be 6061-T6 alloy. Splice and reinforcing sleeves, brackets, end caps, toeboards, etc, shall be aluminum alloy 6063-T6 or 6061-T6. Cast fittings shall be aluminum alloy No. 214. Railing system fastening hardware shall be Type 316 stainless steel. After welding, aluminum shall be anodized. All railing, posts, toeboards and exposed aluminum shall be anodized with an architectural Class I satin finish providing a minimum coating thickness of 0.7 mils and a minimum coating weight of 32 milligrams per square inch in compliance with AA M12C22A41.
C. Railings shall be 2 rail welded railing systems, as shown on the Drawings, fabricated with 1- 1/2-in nominal diameter pipe. Posts shall be Schedule 80 pipe, minimum and rails and handrail shall be Schedule 40 pipe, minimum. Posts and top rails shall be continuous. Spacing of posts shall not exceed 5-ft on center and shall be uniformly spaced except as otherwise shown on the Drawings. Posts will be required on each side of structure expansion joints. All railing posts shall be vertical.
D. Welds shall be circumferential welds ground smooth and even to produce a railing that is neat in appearance and structurally sound. Welding methods shall be in conformity with AWS standards for the materials being joined. All rails to post connections shall be coped and fastened by continuous welds. There shall be no burrs, sharp edges or protrusions on any weld on any part of the handrail system. After fabrication, the welds and surrounding area shall be cleaned and hand buffed to blend with the adjacent finish. All mechanical fasteners shall be unobtrusively located in countersunk holes with the top flush with the surface of the rail. Bends in the railing shall be as indicated by the Drawings. No distortion of the circular railing shape will be allowed. Bends and terminal sections shall be made without the use of fittings. Corner bends shall be mitered and welded bends.
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E. Railing shall be assembled in sections as long as practical but shall not be greater than 24-ft in length. A field splice shall be used when an assembled section is to be attached to another section.
1. Field splices shall use internal splice sleeves located within 8-in of railing posts. The sleeve shall be welded to the rail on one side and fastened with a set screw to the rail on other side. The field splice shall be detailed to take the differential expansion between the railing system and the supporting structure.
F. The bases or supports for railing posts and handrail shall be the types indicated on the Drawings.
G. Safety gates, for railing openings, shall be fabricated of matching pipe and rail material and configuration. The gates shall be self-closing gates with approved stop, latch and stainless steel closure spring and hinges.
H. Barrier chains, for railing openings, shall be fabricated of stainless steel chains. Chain shall be 1/4-in stainless steel links, with eleven links per foot as manufactured by Eastern Chain Works, Inc., NY; Lawrence Metal Products, Inc. or equal. Chains shall be fastened to the handrail posts at the elevation of each rail. One end of each chain shall be connected to one post with a 1/4-in diameter stainless steel eye bolt and the other end shall be connected to the other post by means of a heavy chromium plated bronze swivel eye slide harness snap and a similar eye bolt.
I. Toeboards shall be provided on all railing adjacent to a drop in elevation of 4-ft or more. Toeboards are not required on the inclined portion of stairway railings or where concrete or steel curbs, 4-in or more in height, are present. Toeboards shall be 4-in high channels of the same material as the railing. The channels shall have a minimum thickness of 1/8-in and have flanges of not less than 3/4-in nor more than 1-1/2-in in width. Toeboards shall be positioned with a maximum clearance of 1/4-in from the floor and fastened to railing posts with 1/4-in stainless steel U-bolts, with J-bolts at corner posts and with clip angles and two 1/4-in stainless steel expansion bolts at walls.
J. All railings shall be properly protected by paper, or by an approved coating or by both against scratching, splashes or mortar, paint, or other defacements during transportation and erection and until adjacent work by other trades has been completed. After protective materials are removed, the surfaces shall be made clean and free from stains, marks, or defects of any kind.
2.06 LADDERS
A. Ladders, ladder accessories and ladder clearances shall conform to the requirements of OSHA.
B. Aluminum ladders shall be fabricated with Schedule 40, 21-in O.D. continuous extruded aluminum pipe side rails spaced a minimum 18-in apart. Rungs shall be 3/4-in diameter aluminum bars spaced 12-in on center. Wall support brackets shall be Type 316 stainless steel spaced 4-ft on center with 1/2-in diameter Type 316 stainless steel expansion anchors. Where possible, the side rails shall be fastened to the floor with 1/2-in diameter Type 316 stainless steel expansion bolts.
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2.07 ACCESS HATCHES
A. Access hatches shall have single or double leaf doors as indicated by the Drawings. The doors shall be 1/4-in aluminum diamond pattern plate with welded stiffeners, as necessary, to withstand a live load of 300 lbs/sq ft with a maximum deflection of 1/150th of the span or as indicated on the Drawings. Hatches shall have a 1/4-in aluminum channel frame with a perimeter anchor flange or strap anchors for concrete embedment around the perimeter. Unless otherwise noted on the Drawings, use pivot torsion bars for counterbalance or spring operators for easy operation along with automatic door hold open. Hardware shall be durable and corrosion resistant with Type 316 stainless steel hardware used throughout. Provide removable lock handle. Finish shall be the factory mill finish for aluminum doors and frames with bituminous coating on the exterior of the frames in contact with concrete. Hatches shall be watertight and have a 1-1/2-in drainage coupling to the channel frame. Access hatches shall be Types as indicated on the Drawings by Bilco Company, New Haven, CT or equal.
2.08 MISCELLANEOUS ALUMINUM
A. All miscellaneous metal work shall be formed true to detail, with clean, straight, sharply defined profiles and smooth surfaces of uniform color and texture and free from defects impairing strength or durability. Holes shall be drilled or punched. Edges shall be smooth and without burrs. Fabricate supplementary pieces necessary to complete each item though such pieces are not definitely shown or specified.
B. Connections and accessories shall be of sufficient strength to safely withstand the stresses and strains to which they will be subjected. Exposed joints shall be close fitting and jointed where least conspicuous. Threaded connections shall have the threads concealed where practical. Welded connections shall have continuous welds or intermittent welds as specified or shown. The face of welds shall be dressed flush and smooth. Welding shall be on the unexposed side as much as possible in order to prevent pitting or discoloration of the aluminum exposed surface. Provide holes for temporary field connections and for attachment of the work of other trades.
C. Miscellaneous aluminum items shall include: beams, angles, closure angles, grates, hatches, floor plates, stop plates, stair nosings and any other miscellaneous aluminum called for on the Drawings and not otherwise specified.
D. Angle frames for hatches, beams, grates, etc, shall be complete with welded strap anchors attached.
E. Aluminum diamond plate and floor plate shall have a minimum thickness of 3/8-in. Frames and supports shall be of aluminum construction. Fastening devices and hardware shall be Type 316 stainless steel. Plates shall have a mill finish.
F. Stair treads for aluminum stairs shall have abrasive non-slip nosing as approved.
G. Aluminum nosing at concrete stairs shall be Wooster Products, Inc.; Alumogrit Treads, Type 116; similar by Barry Pattern and Foundry Co.; Andco or equal. Furnish with wing type anchors and flat head stainless steel machine screws, 12-in on center. Nosing shall also be used at concrete ladder openings. Nosing shall a single piece for each step extending to within
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3-in at each side of stair or full ladder width. Set nosing flush with stair tread finish at concrete stairs. Furnish treads with heavy duty protective tape cover.
2.09 MISCELLANEOUS STEEL
A. All miscellaneous metal work shall be formed true to detail, with clean, straight, sharply defined profiles and smooth surfaces of uniform color and texture and free from defects impairing strength or durability. Holes shall be drilled or punched. Edges shall be smooth and without burrs. Fabricate supplementary pieces necessary to complete each item though such pieces are not definitely shown or specified.
B. Connections and accessories shall be of sufficient strength to safely withstand the stresses and strains to which they will be subjected. Exposed joints shall be close fitting and jointed where least conspicuous. Threaded connections shall have the threads concealed where practical. Welded connections shall have continuous welds or intermittent welds as specified or shown. The face of welds shall be dressed flush and smooth. Provide holes for temporary field connections and for attachment of the work of other trades.
C. Miscellaneous steel items shall include: beams, angles, lintels, metal stairs, support brackets, base plates for other than structural steel or equipment, closure angles, bridge crane rails, monorail hoist beams, holddown straps and lugs, door frames, splice plates, subframing at roof openings and any other miscellaneous steel called for on the Drawings and not otherwise specified.
D. Structural steel angle and channel door frames shall be galvanized. Frames shall be fabricated with not less than three anchors on each jamb.
E. Steel pipe pieces for sleeves, lifting attachments and other functions shall be Schedule 40 pipe unless otherwise shown on the Drawings. Wall and floor sleeves, of steel pipe, shall have welded circumferential steel waterstops at mid-length.
F. Lintels, relief angles or other steel supporting masonry or embedded in masonry shall be galvanized.
G. All steel finish work shall be thoroughly cleaned, by effective means, of all loose mill scale, rust and foreign matter and shall be given one shop coat of primer compatible with the finish coat after fabrication but before shipment. Paint shall be omitted within 3-in of proposed field welds. Paint shall be applied to dry surfaces and shall be thoroughly and evenly spread and well worked into joints and other open spaces.
H. Galvanizing, where required, shall be the hot-dip zinc process after fabrication. Coating shall be not less than 2 oz/sq ft of surface.
2.10 MISCELLANEOUS STAINLESS STEEL
A. All miscellaneous metal work shall be formed true to detail, with clean, straight, sharply defined profiles and smooth surfaces of uniform color and texture and free from defects impairing strength or durability. Holes shall be drilled or punched. Edges shall be smooth and without burrs. Fabricate supplementary pieces necessary to complete each item though such pieces are not definitely shown or specified.
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B. Connections and accessories shall be of sufficient strength to safely withstand the stresses and strains to which they will be subjected. Exposed joints shall be close fitting and jointed where least conspicuous. Threaded connections shall have the threads concealed where practical. Welded connections shall have continuous welds or intermittent welds as specified or shown. The face of welds shall be dressed flush and smooth. Provide holes for temporary field connections and for attachment of the work of other trades.
C. Miscellaneous stainless steel items shall include: beams, angles, bar racks and any other miscellaneous stainless steel called for on the Drawings and not otherwise specified.
2.11 CASTINGS
A. Casting shall be of good quality, strong, tough, even-grained, smooth, free from scale, lumps, blisters, sand holes and defects of any kind which render them unfit for the service for which they are intended. Castings shall be thoroughly cleaned and will be subjected to a hammer inspection in the field by the Engineer. All matching surfaces shall be machined to a true plane surface to allow contact surfaces to seat at all points without rocking. Allowances shall be made in the patterns so that the thickness specified shall not be reduced in obtaining finished surfaces. Castings will not be acceptable if the actual weight is less than 95 percent of the theoretical weight computed from dimensions. The Contractor shall provide facilities for weighing castings in the presence of the Engineer.
B. Frames, covers, cast grates and trench drains for structures shall be gray iron castings except as otherwise specified or indicated on the Drawings. Sizes shall be as shown on the Drawings. Covers shall have letters "WATER," "SANITARY SEWER," or DRAIN," as applicable, embossed on top.
C. Frames and covers for installation in slabs shall be heavy duty, R-6013-R-6099. Series as manufactured by Neenah Foundry Co., or equal.
D. Electrical and telephone manhole and handhole frames and covers for structures shall be ductile iron castings. The covers shall be watertight. Covers shall have the word "ELECTRIC," "HIGH VOLTAGE," "LOW VOLTAGE," "SIGNAL," "TELEPHONE," as applicable, embossed on or cast into the top in letters 2-in high. The clear opening shall be 36- in unless otherwise indicated on the Drawings.
E. Trench drains shall be of the length shown on the Drawings and shall be heavy duty, R-4990 Series with a "Type A" cover as manufactured by Neenah Foundry Co. or equal.
PART 3 EXECUTION
3.01 INSTALLATION
A. Install all items except those to be embedded in concrete or other masonry which shall be installed under Division 3 and Division 4 respectively. Items to be attached to concrete or masonry after such work is completed shall be installed in accordance with the details shown. Fastening to wood plugs in masonry will not be permitted.
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B. Abrasions in the shop primer shall be touched up immediately after erection. Areas left unprimed for welding shall be painted with primer after welding.
C. Zinc coating which has been burned by welding, abraded, or otherwise damaged shall be cleaned and repaired after installation. The damage area shall be thoroughly cleaned by wire brushing and all traces of welding flux and loose or cracked zinc coating removed prior to painting. The cleaned area shall be painted with two coats of zinc oxide-zinc dust paint conforming to the requirements of Military Specifications MIL-P-15145. The paint shall be properly compounded with a suitable vehicle in the ratio of one part zinc oxide to four parts zinc dust by weight.
D. Specialty products shall be installed in accordance with the Manufacturer’s recommendations.
E. Expansion bolts shall be checked for tightness a minimum of 24 hours after initial installation.
F. Install adhesive capsule anchors using Manufacturer’s recommended drive units and adapters and in compliance with the Manufacturer’s recommendations.
G. Headed anchor studs shall be welded in accordance with Manufacturer’s recommendations.
H. All railings shall be erected to line and plumb.
I. All steel surfaces that come into contact with exposed concrete or masonry shall receive a protective coating of an approved heavy bitumastic troweling mastic applied in accordance with the Manufacturer’s instructions prior to installation.
J. Where aluminum contacts a dissimilar metal, apply a heavy brush coat of zinc-chromate primer followed by two coats of aluminum metal and masonry paint to the dissimilar metal.
K. Where aluminum contacts masonry or concrete, apply a heavy coat of approved alkali resistant paint to the masonry or concrete.
L. Where aluminum contacts wood, apply two coats of aluminum metal and masonry paint to the wood.
M. Between aluminum gratings, aluminum stair treads, or aluminum handrail brackets and steel supports, insert 1/4-in thick neoprene isolator pads, 85 plus or minus 5 Shore A durometer, sized for full width and length of bracket or support.
END OF SECTION
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SECTION 09901
SURFACE PREPARATION AND SHOP PRIME PAINTING
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required for the surface preparation and application of shop primers on ferrous metals, excluding stainless steels, as specified herein.
1.02 RELATED WORK
A. Finish painting is included in Section 09902.
1.03 SUBMITTALS
A. Submit, in accordance with Section 01300, shop drawings, manufacturer's specifications and data on the proposed primers and detailed surface preparation, application procedures and dry mil thicknesses.
B. Submit representative physical samples of the proposed primers, if required by the Engineer.
1.04 REFERENCE STANDARDS
A. The Society for Protective Coatings (SSPC)
1. SSPC-SP 6/NACE No. 3 - Joint Surface Preparation Standard SSPC-SP 6/NACE No. 3: Commercial Blast Cleaning
2. SSPC-SP 10/NACE No. 2 - Joint Surface Preparation Standard SSPC-SP 10/NACE No. 2: Near-White Blast Cleaning.
B. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.
PART 2 PRODUCTS
2.01 MATERIALS
A. Submerged Surfaces - Shop primer for ferrous metals which will be in contact with water being treated, either submerged or which are subject to splash action or which are specified to be considered submerged service shall be shop primed with the following:
1. Shop Prime Coat: (Zinc Micaceous Iron Oxide Polyurethane Aromatic Shop Primer)
a. TNEMEC: Series 1 Omnithane
b. Carboline: Carboguard 561
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c. Sherwin-Williams Company (The): Corothane I Zinc Primer 1K Mio-Zinc.
d. PPG PMC Durathane MCZ 97-679 Series or PPG PMC Amerlock 400.
e. Or equal.
B. Non-Submerged Surfaces: Shop primer for ferrous metals which will be in contact with water being treated, not submerged and not subject to splash action shall be shop primed with the following:
1. Shop Prime Coat: (Zinc Micaceous Iron Oxide Polyurethane Aromatic Shop Primer)
a. TNEMEC: Series 1 Omnithane
b. Carboline: Carboguard 561
c. Sherwin-Williams Company (The): Corothane I Zinc Primer 1K Mio-Zinc.
d. PPG PMC Durathane MCZ 97-679 Series or PPG PMC Amercoat 68HS
e. Or equal.
C. Submerged Surfaces:
1. Shop Prime Coat for Ductile Iron Pipe: (Epoxy, Polyamidoamine Shop Primer)
a. TNEMEC: Series N140 Pota-Pox-Plus
b. Carboline: Carboguard 561
c. Sherwin-Williams Company (The): Macropoxy 846 NSF Winter Grade Epoxy Mill White
d. PPG PMC Aquapon HB Potable Water Epoxy Coating 95-132 Series or PPG PMC Amerlock 2 Epoxy.
e. Or equal.
2. Shop Prime Coat for Ferrous Metal Surfaces: (Zinc Micaceous Iron Oxide Polyurethane Aromatic Shop Primer)
a. TNEMEC: Series 1 Omnithane
b. Carboline: Carboguard 561
c. Sherwin-Williams Company (The): Corothane I Zinc Primer 1K Mio-Zinc.
d. PPG PMC Durathane MCZ 97-679 Series
e. Or equal.
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D. Non-Primed Surfaces - Gears, bearings surfaces and other similar surfaces obviously not to be painted shall be given a heavy shop coat of grease or other suitable rust-resistant coating. This coating shall be maintained as necessary to prevent corrosion during all periods of storage and erection and shall be satisfactory to the Engineer up to the time of the final acceptance test.
E. Compatibility of Coating Systems - Shop priming shall be done with primers that are guaranteed by the manufacturer to be compatible with their corresponding primers and finish coats specified in Section 09902 for use in the field and which are recommended for use together.
PART 3 EXECUTION
3.01 APPLICATION
A. Surface Preparation and Priming
1. Non-submerged components scheduled for priming, as defined above, shall be blast cleaned in accordance with SSPC-SP 6/NACE No. 3, immediately prior to priming. Submerged components scheduled for priming, as defined above, shall be blast cleaned in accordance with SSPC-SP 10/NACE No. 2 , immediately prior to priming. Consult manufacturer regarding required surface profiles.
2. Surfaces shall be dry and free of dust, oil, grease and other foreign material before priming.
3. Shop prime in accordance with approved manufacturer's recommendations.
B. Non-Primed Surfaces
1. Apply approved coating per manufacturer's recommendations.
3.02 FABRICATED ITEMS
A. All items to be shop primed shall be blast cleaned as specified for applicable service prior to priming. If, in the opinion of the Engineer, any prime coating that has been improperly applied or if material contrary to this Section has been used, that coating shall be removed by abrasive blasting to white metal and reprimed in accordance with this Section.
B. All shop prime coats shall be of the correct materials and applied in accordance with this Section. Remove any prime coats not in accordance with this Section by blast cleaning and apply the specified prime coat at no additional cost to the Owner.
C. Shop primed surfaces shall be cleaned thoroughly and damaged or bare spots prepared as approved and retouched with the specified primer before the application of successive paint coats in the field.
D. Shop finish coats, if proposed and allowed, shall be equal in appearance and protection quality to a field applied finish coat. If, in the opinion of the Engineer, a shop finish coat system does not give the appearance and protection quality of other work of similar nature, prepare the surfaces and apply the coat or coats of paint as directed by the Engineer to accomplish the
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desired appearance and protection quality. Submit to the Engineer substantial evidence that the standard finish is compatible with the specified finish coat.
E. Properly protect the shop prime and finish coats against damage from weather or any other cause.
F. Wherever fabricated equipment is required to be blast cleaned, protect all motors, drives, bearings, gears, etc, from the entry of grit. Equipment found to contain grit shall be promptly and thoroughly cleaned.
END OF SECTION
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SECTION 09902
PAINTING
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all materials, labor, equipment and incidentals required and performing all the painting necessary to complete this Contract in its entirety.
B. It is the intent of these Specifications to paint all new interior concrete where scheduled, exposed miscellaneous metal, pipe, fittings, supports, valves, equipment and all other work obviously required to be painted unless otherwise specified. Minor items omitted in the schedule of work shall be included in the work of this Section where they come within the general intent of the specifications as stated herein.
C. The following surfaces or items are not required to be painted:
1. Portions of metal, other than aluminum, embedded in concrete. This does not apply to the back face of items mounted to concrete or masonry surfaces which shall be painted before erection. Aluminum to be embedded in or in contact with concrete or masonry shall be coated to prevent electrolysis.
2. Stainless steel.
3. Fencing.
4. Concealed surfaces of pipe or crawl spaces.
5. Acoustical ceilings.
6. Tile.
7. Exterior concrete, unless otherwise specified and heavy duty concrete topping.
8. Finish hardware, except door closers that are not stainless steel.
9. Manhole frames and covers.
10. Fiberglass other than piping.
11. Packing glands and other adjustable parts and nameplates of mechanical equipment.
D. The work will be performed at an existing operating facility. It will be necessary that contaminants, including dust from abrasive blasting, solvents, thinners, paints, etc., shall be kept from the treatment process and from the existing operating equipment, motors, valves, etc. The Contractor shall take whatever precautions are necessary to prevent contamination of the water supply at all times during this Contract.
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1.02 RELATED WORK
A. Concrete finishes are specified in Division 3.
B. Shop priming and surface preparation of ferrous metals are specified in Section 09901 and included in the respective Section with the item to be primed.
1.03 SUBMITTALS
A. Submit, in accordance with Section 01300, shop drawings, working drawings and product data including Manufacturer's specifications and data on the proposed paint systems and detailed surface preparation, application procedures and dry film thickness.
B. Furnish one 8-in by 4-in by 16-in concrete block with one coat of the proposed coating system in a color selected by the Owner. A 4-ft by 4-ft section of concrete or steel structure to be painted shall be designated as a test panel for each different coating system to be applied on water retaining concrete structures or steel structures. These samples and test panels, when approved by the Engineer, will establish the quality of the painted surface where this ap- plication is indicated. The Engineer may require the Contractor to construct test panels for different coating systems at no additional cost to the Owner.
C. Submit, in accordance with Section 01300, color cards, including standard and special colors, for initial color selections.
D. Schedule of Painting Operations: Submit for review, within 90 days after the Notice to Proceed, a complete Schedule of Painting Operations. This Schedule is imperative so that the various fabricators may be notified of the proper shop prime coat to apply. Properly notify and coordinate the fabricators' surface preparation and painting operations with these Specifications. This Schedule shall include for each surface to be painted, the brand name, the percent volume of solids, the coverage and the number of coats the Contractor proposes to use in order to achieve the specified dry film thickness, and color charts. When the Schedule has been approved, apply all material in strict accordance with the approved Schedule and the Manufacturer's instructions. Wet and dry paint film gauges shall be made available to the Engineer to verify the proper application while work is in progress.
1.04 REFERENCES STANDARDS
A. The work herein specified shall be performed in a legally acceptable manner and it shall be the responsibility of the Contractor to obtain any and all licenses, permits and legal approvals required to perform the work specified.
B. American Society for Testing and Materials (ASTM)
1. ASTM D4417 - Standard Method for Field Measurement of Surface Profile of Blast Cleaned Steel.
2. ASTM D4258 - Surface Cleaning Concrete for Coating.
3. ASTM D4259 - Abrading Concrete.
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4. ASTM D4263 - Standard Test Method for Indicating Moisture in Concrete by the Plastic Sheet Method.
5. ASTM D4285 - Indicating Oil or Water in Compressed Air.
C. American Water Works Association (AWWA)
D. National Association of Corrosion Engineers (NACE)
1. RP-0188-88 - Standard Recommended Practice for Discontinuity (Holiday) Testing of Protective Coatings.
E. Steel Structures Painting Council (SSPC)
1. SSPC-SP-1 - Solvent Cleaning.
2. SSPC-SP-2 - Hand Tool Cleaning.
3. SSPC-SP-6 - Commercial Blast Cleaning.
4. SSPC-SP-10 - Near-White Blast Cleaning.
5. SSPC-PA-2 - Measurement of Dry Paint Thickness with Magnetic Gauges.
F. Occupational Safety and Health Act (OSHA)
G. National Sanitation Foundation (NSF)
H. American Association of State Highway and Transpiration Officials (AASHTO)
I. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.
1.05 SPARE MATERIAL
A. Furnish one unopened gallon can of each type and each color of paint used.
1.06 PRE-PAINTING CONFERENCE
A. Well in advance of commencement of painting operations, but after required submittals are reviewed, a pre-painting conference shall be held. All parties with an interest in the painting work shall attend including the Contractor, the paint Manufacturer, the Owner, the Engineer and the painting subcontractor and his foreman. The Contractor shall contact each party and arrange the meeting.
B. The conference shall include an inspection of the areas to be painted by all parties and a discussion of the conformance of each area with the specifications. Important issues such as environmental conditions, climate control systems, original primer dry film thickness, and monitoring the number of coats that have been field applied shall be discussed and problems shall be resolved.
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C. A written record of the meeting shall be submitted to the Engineer by the Contractor.
1.07 SAFETY
A. Comply with all applicable Laws, Codes, Standards, and Ordinances, Rules, Regulations, Lawful Orders of Public Authorities as they apply to Safety procedures under Federal, State and Local Jurisdiction. B. Maintain a safe workplace and enforce a continuous safety program to provide protection against potential hazards. All personnel must be made aware of hazards and the precautions against them.
PART 2 PRODUCTS
2.01 MATERIALS
A. All painting materials shall be fully equal to those manufactured by the Tnemec Company Inc.; the Kop-Coat Company, Inc. or Porter Paint Company. The painting schedule has been prepared on the basis of Tnemec, Porter and Kop-Coat products and recommendations for applications. No brand other than those named will be considered for approval unless the brand and type of paint proposed for each item in the following schedule together with sufficient data substantiated by certified tests conducted at no expense to the Owner, to demonstrate its equality to the paint(s) named, is submitted in writing to the Engineer for approval within 30 days after the signing of the Notice to Proceed. The type and number of tests performed shall be subject to the Engineer's approval.
B. All painting materials shall be delivered to the mixing area in unbroken containers, bearing the Manufacturer's brand, date of manufacture and name. They shall be used without adulteration and mixed, thinned, and applied in strict accordance with Manufacturer's directions for the applicable materials and surface and with the Engineer's approval before using.
C. Shop priming shall be done with primers that are guaranteed by the Manufacturer to be compatible with the finish paints to be used. Refer to Section 09901 for special primers.
D. No paint containing lead will be allowed. Oil shall be pure boiled linseed oil.
E. Work areas will be designated by the Engineer for storage and mixing of all painting materials. Materials shall be in full compliance with the requirements of pertinent codes and fire regulations. Proper containers outside of the buildings shall be provided and used for painting wastes and no plumbing fixture shall be used for this purpose.
F. All recommendations of the paint Manufacturer in regard to the health and safety of workmen shall be followed.
G. All painting materials and required coatings shall be certified for contact with potable water by the Florida Department of Environmental Protection, U.S. EPA and the NSF.
2.02 PAINTING SYSTEMS
A. All colors will be selected by the Engineer from color charts submitted by the Contractor.
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B. The following surfaces shall have the types of paint scheduled below applied at the dry film thickness (DFT) in mils per coat noted. The term "DFT" means minimum dry film thickness. The maximum thickness shall be 150 percent of the minimum specified, i.e. 5 mils DFT will be 7.5 mils maximum. Some colors will require an additional coat from what is listed to get the proper color coverage.
1. Ferrous metals submerged or subject to splashing: Note: Brush apply a "striped coat" over all welded joints prior to the first coat.
a. Tnemec
1) 1 Coat: 139-1255 High Solids Catalyzed Epoxy (7 DFT)
2) 1 Coat: 139-AA90 High Solids Catalyzed Epoxy (8 DFT)
b. Kop-Coat
1) 1 Coat: Kop-Coat-Gray Super Hi-Gard Epoxy (7 DFT)
2) 1 Coat: Kop-Coat-Color Super Hi-Gard Epoxy (8 DFT)
c. Porter
d. 1 Coat: Magna-Coat Epoxy (7 DFT)
e. 1 Coat: Magna-Coat Epoxy (8 DFT)
2. Exterior nonsubmerged ferrous metals: Note: Brush apply a "striped coat" over all welded joints prior to the first coat.
a. Tnemec
1) 1 Coat: 66-Color Hi-Build Epoxoline (4 DFT)
2) 1 Coat: 71-Color Endura Shield (2.5 DFT)
b. Kop-Coat
1) 1 Coat: Higard Epoxy (4 DFT)
2) 1 Coat: 1122 BRS Linear Polyurethane (2.5 DFT)
c. Porter
1) 1 Coat: M.C.R. 65 High Solids Epoxy (4 DFT)
2) 1 Coat: Hythane 4600 Series Polyurethane (2.0 DFT)
3. Interior nonsubmerged ferrous metals: Note: Brush apply a "striped coat" over all welded joints prior to the first coat.
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a. Tnemec
1) 1 Coat: 66-1211 Hi-Build Epoxoline (5 DFT)
2) 1 Coat: 66-Color Hi-Build Epoxoline (6 DFT)
b. Kop-Coat
1) 1 Coat: Higard-Gray Epoxy (5 DFT)
2) 1 Coat: Higard-Color Epoxy (6 DFT)
c. Porter
1) 1 Coat: Magna-Coat Epoxy (5 DFT)
2) 1 Coat: Magna-Coat Epoxy (6 DFT)
4. Exterior galvanized, and non-ferrous metal:
a. Tnemec
1) 1 Coat: 66-Color Hi-Build Epoxoline (4 DFT)
2) 1 Coat: 71-Color Endura-Shield (2.5 DFT)
b. Kop-Coat
1) 1 Coat: Higard Epoxy (4 DFT)
2) 1 Coat: 1122 BRS Linear Polyurethane (2.5 DFT)
c. Porter
1) 1 Coat: M.C.R. 43 Hibuild Primer 4336 (5 DFT)
2) 1 Coat: Hythane 4600 Series Polyurethane (2.0 DFT)
5. Interior Galvanized, and non-ferrous metals:
a. Tnemec
1) 1 Coat: 66-1211 Epoxoline Primer (5 DFT)
2) 1 Coat: 66-Color Hi-Build Epoxoline (6 DFT)
b. Kop-Coat
1) 1 Coat: Higard-Gray Epoxy (5 DFT)
2) 1 Coat: Higard-Color Epoxy (6 DFT)
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c. Porter
1) 1 Coat: Magna-Coat Epoxy (5 DFT)
2) 1 Coat: Magna-Coat Epoxy (6 DFT)
6. Galvanized and non-ferrous metal submerged or subject to splashing:
a. Tnemec
1) 1 Coat: 20-1211 Pota Pox Primer (4 DFT)
2) 1 Coat: 20-AA90 Pota Pox (5 DFT)
b. Kop-Coat
1) 1 Coat: Kop-Coat 40 Passivator (0.5 DFT max.)
2) 1 Coat: Higard-Gray Epoxy (5 DFT)
3) 1 Coat: Higard-Color Epoxy (6 DFT)
c. Porter (sweep blast to 1.5 mils before application)
1) 1 Coat: M.C.R. 43 Epoxy Primer (2 DFT)
2) 1 Coat: Magna-Coat Epoxy (6 DFT)
3) 1 Coat: Magna-Coat Epoxy (6 DFT)
7. Aluminum in contact with dissimilar metals:
a. Tnemec
1) 2 Coats: 66-Color Hi-Build Epoxoline (3 DFT per coat)
b. Kop-Coat
1) 2 Coats: Higard Epoxy (3 DFT per coat)
c. Porter
1) 2 Coats: Magna-Coat Epoxy (3 DFT per coat)
8. Plastic Piping - Interior:
a. Tnemec
1) 2 Coats: 66-Color Hi-Build Epoxoline (3 DFT per coat)
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b. Kop-Coat
1) 2 Coats: Higard Epoxy (3 DFT per coat)
c. Porter
1) 2 Coats: M.C.R. 65 High Solids Epoxy (3 DFT per coat)
9. Plastic Piping - Exterior
a. Tnemec
1) 1 Coat: 66-Color Hi-build Epoxoline (4 DFT)
2) 2 Coats: 71-Color Endura Shield (2.5 DFT per coat)
b. Kop-Coat
1) 1 Coat: Higard Epoxy (4 DFT)
2) 1 Coat: 1122 BRS Linear Polyurethane (2.5 DFT)
c. Porter
1) 1 Coat: M.C.R. 43 Hibuild Primer 4336 (5 DFT)
2) 2 Coats: Hythane 4600 Series Polyurethane (2.0 DFT per coat)
C. Any surfaces not specifically named in the Schedule and not specifically excepted shall be prepared, primed and painted in the manner and with materials consistent with these Specifications. The Engineer shall select which of the Manufacturer's products, whether the type is indicated herein or not, shall be used for such unnamed surfaces. No extra payment shall be made for this painting.
2.03 METAL TAGS
A. For pipelines smaller than 3/4-in in diameter, securely fasten metal tags, 2-1/2-in x -in, of 17 Birmingham Stubs Gage Brass with lettering etched and filled with enamel. Tags shall be approved by the Engineer.
PART 3 EXECUTION
3.01 PREPARATION OF SURFACES
A. General: All surfaces to be painted shall be prepared as specified herein or in Section 09901 and shall be dry and clean before painting. Surfaces which are not to receive coating shall be protected during surface preparation, cleaning and coating operations.
B. New Ferrous Metal (Not Galvanized):
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1. Carbon steel surfaces shall be ground smooth and clear of all sharp edges, rough welds, pinholes, burrs, weld splatter, laminations, etc. The profile on the steel shall be restored if grinding is done after abrasive blasting.
2. Surfaces which are to be submerged shall be abrasive blasted in accordance with SSPC-SP-10. Nonsubmerged surfaces shall be abrasive blasted in accordance with SSPC-SP-6.
3. Anchor profile shall be measured in accordance with Method C of ASTM D4417. Anchor profile shall be as specified by the coating Manufacturer. In the absence of such requirements, the following shall be used:
a. Minimum Anchor profile: 1.5 mils.
b. Maximum Anchor profile: 2.5 mils.
4. Grease, oil, foreign matter, dust, etc., shall be removed before blasting or painting. Method of removal must be approved by the Engineer.
5. Cleaning shall cease each day to allow work to be primed. Primer shall be applied within 6 hours after blasting or before flash rusting. If rusting occurs, surface shall be re-blasted.
6. Permission shall be required for blasting if relative humidity exceeds 85 percent or if temperature of the surface is within 5 degrees F of the dew point.
7. Dry blasting shall not be carried out on surfaces which will be wet before painting.
8. All blasting equipment shall be in accordance with OSHA, Plant and Local Safety requirements.
9. Equipment shall have automatic moisture traps and drains.
10. Air fed hoods shall be used and have appropriate filters and carbon monoxide monitors on air line.
11. "DEAD MAN HANDLES" shall be used.
12. Pressure vessel wall thicknesses shall be checked at least annually.
13. Hoses shall be static dissipating.
14. Blasting pots shall be grounded.
C. Concrete: Concrete surfaces shall have been finished as specified in Division 3. Report unsatisfactory surfaces to the Engineer. Concrete shall be free of dust, oil, curing compounds and other foreign matter. Special care shall be given to thoroughly clean interior concrete and concrete block surfaces of all marks before application of finish.
1. All concrete surfaces shall be abrasive blasted and prepared prior to painting. Remove the surface laitance and any contaminants in the concrete mix that may have floated to
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the surface of new concrete. Remove any existing materials, laitance and weak and contaminated concrete of old concrete. New concrete is concrete placed under this general contract while old concrete is concrete in place prior to this contract. Concrete shall have consistent even texture (void free) and shall be patched where needed to fill voids prior to painting.
2. Remove grease, oil and other penetrating contaminants in accordance with ASTM D4258.
3. Provide ventilation to dry concrete surfaces. Moisture shall be determined in accordance with ASTM D4263.
4. Inspect concrete surfaces for cracks and possible water leakage. Repair with cement plug or epoxy grout. Grind all cracks to a "V" prior to repairing.
5. Grind all fins and protrusions.
6. All surfaces shall be prepared in accordance with ASTM D4259 using the abrasive blast cleaning procedure. This can normally be accomplished with 40 to 80 mesh abrasive using clean dry air. Air cleanliness shall be determined in accordance with ASTM D4285. Pressure at blasting nozzle shall not exceed 80 psi. Do not concentrate blast on surface but move at a fairly rapid rate to provide a surface free of latents and contaminants. An alternate method of surface preparation on horizontal surfaces is the use of automatic blasting equipment such as "Blastrack", or scarifier.
7. Blasting Equipment shall be the same as that in Paragraph B "New-ferrous metal".
D. Concrete block surface shall be smooth and cleaned of all mortar flash, dust, efflorescence, chalk, loose mortar, dirt, grease, oil, tar and other foreign matter.
E. All plastic pipe surfaces shall be lightly sanded before painting.
F. Wood surfaces shall be dry. Sand to obtain a smooth surface. All encrustations shall be removed.
G. Exposed Pipe: Bituminous coated pipe shall not be used in exposed locations. Pipe which shall be exposed after project completion shall be primed in accordance with the requirements herein. Any bituminous coated pipe which is inadvertently installed in exposed locations shall be abrasive blasted before priming and painting. After installation all exterior, exposed flanged joints shall have the gap between adjoining flanges sealed with a single component polysulfide sealant to prevent rust stains.
H. Primed or Previously Painted Surfaces and Nonferrous Surfaces: All coated surfaces shall be cleaned prior to application of successive coats. All nonferrous metals not to be coated shall be cleaned. This cleaning shall be done in accordance with SSPC-SP-1.
I. Shop-Finished Surfaces: All shop-coated surfaces shall be protected from damage and corrosion before and after installation by treating damaged areas immediately upon detection. Abraded or corroded spots on shop-coated surfaces shall be "Hand Cleaned" in accordance with SSPC-SP-2 and then touched up with the same materials as the shop coat. All shop coated surfaces which are faded, discolored, or which require more than minor touch-up in the
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opinion of the Engineer shall receive new surface preparation before being repainted. Cut edges of galvanized sheets and exposed threads and cut ends of galvanized piping, electrical conduit and metal pipe sleeves, that are not to be finished painted, shall be "Solvent Cleaned" in accordance with SSPC-SP-1 and primed with zinc dust-zinc oxide metal primer.
J. Galvanized and Zinc-Copper Alloy Surfaces: These surfaces to be painted shall be "Solvent Cleaned" in accordance with SSPC-SP-1 and treated as hereinafter specified. Such surfaces not to be painted shall be "Solvent Cleaned."
K. Aluminum embedded or in contact with concrete must be painted with one shop coat of zinc chromate followed by one heavy coat of aluminum pigmented asphalt paint.
3.02 WORKMANSHIP
A. General
1. Primer (spot) and paint used for a particular surface shall, in general, be as scheduled for that type of new surface. Confirm with the paint Manufacturer that the paint proposed for a particular repaint condition will be compatible with the existing painted surface. Sample repainted areas on the actual site will be required to ensure this compatibility. Finished repainted areas shall be covered by the same guarantee specified for remainder of work.
2. At the request of the Engineer, samples of the finished work prepared in strict accordance with these Specifications shall be furnished and all painting shall be equal in quality to the approved samples. Finished areas shall be adequate for the purpose of determining the quality of workmanship. Experimentation with color tints shall be furnished to the satisfaction of the Engineer where standard chart colors are not satisfactory.
3. Protection of furniture and other movable objects, equipment, fittings and accessories shall be provided throughout the painting operations. Canopies of lighting fixtures shall be loosened and removed from contact with surface, covered and protected and reset upon completion. Remove all electric plates, surface hardware, etc., before painting, protect and replace when completed. Mask all machinery name plates and all machined parts not receiving a paint finish. Dripped or spattered paint shall be promptly removed. Lay drop cloths in all areas where painting is being done to adequately protect flooring and other work from all damage during the operation and until the finished job is accepted.
4. On metal surfaces coating thickness shall be determined with magnetic dry film thickness gauge calibrated in accordance with SSPC-PA-2. The number of readings will be a minimum of that stated in SSPC-PA-2. Deficiencies in film thickness shall be corrected by the application of an additional coat(s). On masonry, application rates will vary according to surface texture, however, in no case shall the Manufacturer's stated coverage rate be exceeded. On porous surfaces, it shall be the painter's responsibility to achieve a protective and decorative finish either by decreasing the coverage rate or by applying additional coats of paint.
5. Coating materials shall be delivered to the job site in the original unopened containers, bearing the Manufacturer's label. A Product Data Sheet and Material Safety Data Sheet
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for all coating, activators, thinners, accelerators and other materials shall be obtained from the Manufacturer for each shipment of materials to the job site. Coating materials shall be stored in a dry, well-ventilated area, not in direct contact with the ground, where the temperature is maintained between 40 and 120 degrees F. Damaged materials and/or materials exceeding the Manufacturer's recommended shelf life shall not be used.
6. Paints shall be mixed in proper containers of adequate capacity. All paints shall be thoroughly mixed before use and shall be kept stirred while using. No unauthorized thinners or other materials shall be added to any paint. Air shall not be used directly for agitation. Pigmented material shall be strained after mixing. Where application equipment has strainers, they should be sized so as to allow pigment to pass but not foreign material. Multiple (2 or more) component catalyzed materials may not be used beyond the recommended pot life.
7. Only skilled painters shall be used on the work and specialists shall be employed where required.
B. Field Priming
1. Steel members, metal castings, mechanical and electrical equipment and other metals which are shop primed before delivery at the site will not require a prime coat on the job. All piping and other bare metals to be painted shall receive one coat of primer before exposure to the weather, which shall be the first coat as specified in the painting schedule. Except that all welded joints shall have brush applied a "striped coat" over the joint before the first coat.
2. Equipment which is customarily shipped with a baked-on enamel finish or with a standard factory finish shall normally be field painted unless the prefinished equipment is specifically color selected and unless the finish has not been damaged in transit or during installation. Surfaces that have been shop painted and have been damaged, or where the shop coats have deteriorated, shall be properly cleaned and retouched before any successive painting is done in the field. All such field painting shall match as nearly as possible the original finish.
C. Field Painting
1. All painting at the site shall be designated as Field Painting.
2. All paint shall be at room temperature before applying and no painting shall be done when the temperature is below 50 degrees F, in dust-laden air, when rain or snow is falling, or until all traces of moisture have completely disappeared from the surface to be painted. Coatings shall not be applied unless the temperature of the surface being coated is, and remains, at least 5 degrees F above the dew point until the coating is dry "to touch". Relative humidity shall be less than 85 percent during application.
3. Corners, sharp edges and welds shall be stripped (an additional coat by brush) prior to application of the specified coat. Coating used for striping shall be the same as that specified for the coat to be applied.
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4. Successive coats of paint shall be tinted so as to make each coat easily distinguishable from each other with the final undercoat tinted to the approximate shade of the finished coat.
5. Finish surfaces shall not show brush marks, lap marks or roller marks, or other irregularities. Undercoats shall be thoroughly and uniformly sanded with No. 00 sandpaper or equal to remove defects and provide a smooth even surface. Top and bottom edges of doors shall be painted and all exterior trim shall be back-primed before installation.
6. Painting shall be continuous and shall be accomplished in an orderly manner so as to facilitate inspection. All exterior concrete and masonry painting shall be performed in one continuous manner structure by structure. Materials subject to weathering shall be prime coated as quickly as possible. Surfaces of exposed members that will be inacces- sible after erection shall be cleaned and painted before erection.
7. All materials shall be applied by spray unless otherwise directed by the Engineer. The Contractor shall be responsible for all damage caused by overspray or drifting. On concrete or masonry, back-rolling after spraying shall be undertaken immediately following each coat to assure that all voids and holes are wet out and fully coated. Back-rolling may be deleted from the final coat if the test panel indicates that the prior coats followed by back-rolling is sufficient to provide a continuous coating without pinholes.
8. All surfaces to be painted as well as the atmosphere in which painting is to be done shall be kept warm and dry by heating and ventilation, if necessary, until each coat of paint has hardened. Any defective paint shall be removed and repainted in accordance with the Engineer's directions.
9. Coating integrity shall be determined in accordance with NACE RP-0188-88 using the low voltage wet sponge test method. All holidays will be clearly marked for repair.
10. Before final acceptance of the work, all damaged surfaces of paint shall be cleaned and repainted as directed by the Engineer. Completed work shall be free from runs, drips, sags, holidays, voids and other imperfections. Finish coats shall provide complete hiding and uniform color. All defective work shall be corrected by the CONTRACTOR or applicator at no cost to the Owner.
11. Damaged coatings, pinholes and holidays shall be feather-edged and repaired in accordance with recommendations of the paint Manufacturer.
12. Number of coats in the specification are a minimum required. Additional coats may be required to obtain the minimum required paint thickness, depending on method of application, difference in Manufacturer's products and atmospheric conditions.
13. Any pipe scheduled to be painted and having received a coating of a tar or asphalt-compound shall be painted with two coats of Kop-Coat Inertol Tar Stop; Porters Tarset Standard 7000 or equal before successive coats are applied per the schedule. Tnemec recommends using 66 Hi-Build Epoxoline over tar, but a test patch must be run initially to test the paint's compatibility with the tar.
5000-79695 09902-13 Florida Governmental Utility Authority Waterway Estates Interconnect 60% Submittal
3.03 COLOR CODING FOR PIPES AND EQUIPMENT
A. When color coding is specified, it shall consist of color code painting and identification of all exposed conduits, trough items and pipelines for the transport of gases, liquid and semi-liquids including all accessories such as valves, insulated pipe coverings, fittings, junction boxes, bus bars, connectors and all operating accessories which are integral to the whole functional mechanical pipe and electrical conduit system. Colors shall be as noted in the Paint and Color Coding Schedules attached at the end of this Section.
B. All hangers and pipe support floor stands shall be painted the same color and with the same paint as the pipe it supports. The system shall be painted up to but not including the flanges attached to the mechanical equipment nor the flexible conduit connected to electrical motors. When more than one pipe system is supported on the same bracket, the bracket shall be painted the same color as the adjacent wall or ceiling. Colors shall be as noted in the Paint and Color Coding Schedule.
C. All systems which are an integral part of the equipment, that is originating from the equipment and returning to the same piece of equipment, shall be painted between and up to but not including, the fixed flanges or connections on the equipment.
D. The color code establishes, defines and assigns a definite color for each category of pipe. Pipelines which are not listed on the Schedule of Color Code Paints shall be assigned a color by the Engineer and shall be treated as an integral part of the Contract.
E. Banding for pipes shall be as specified in the Paint and Color Coding Schedule. Bands shall be two inches wide and spaced at two feet on center.
3.04 LETTERING OF TITLES
A. Each pipe system shall be labeled with the name of the materials in each pipeline and alongside this an arrow indicating the direction of flow of liquids. Titles shall be as so described in attached schedule. Titles shall not be located more than twenty linear feet apart except that piping containing hazardous chemicals shall be labeled at no more than ten feet apart and shall also appear directly adjacent to each side of any wall the pipeline breaches, adjacent to each side of the valve regulator, flowcheck, strainer cleanout and all pieces of equipment.
B. Titles shall identify the contents by complete name. Identification title locations shall be determined by the Engineer but in general they shall be placed where the view is unobstructed and on the two lower quarters of pipe or covering where they are overhead. Titles should be clearly visible from operating positions, especially those adjacent to control valves.
C. Titles on equipment shall be applied at eye level on machines where possible or at the upper most broad vertical surface of low equipment. Where more than one piece of the equipment item to be titled exists, the items shall be numbered consecutively as indicated on the mechanical drawings or as directed by the Engineer, for example Pump No. 1; Pump No. 2, etc. Titles shall be composed and justified on the left hand side as follows:
D. Pump No. 1
E. Application of titles.
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1. The color of the titles shall be black or white, as approved, to best contrast with the color of the pipes and equipment and shall be stencil applied.
2. Stencil text is to be in ALL CAPS worded exactly as shown in the Schedule. Titles are to be printed in a single line.
3. Letter sizes.
Outside Diameter of Pipe or Size of Legend Covering (in.) Letters (in.) 3/4 to 1-1/4 1/2 1-1/2 to 2 3/4 2-1/2 to 6 1-1/4 8 to 10 2-1/2 More than 10 3-1/2
Equipment titles are to be two inches high.
4. Arrow sizes. Where "a" is equal to 3/4 of outside diameter of pipe or covering, the arrow shaft shall be 2 "a" long by 3/8 "a" wide. The arrow head shall be an equilateral triangle with sides equal to "a." Maximum "a" dimension shall be 6-in.
5. When using direction arrows, point arrowhead away from pipe markers and in direction of flow. If flow can be in both directions, use a double-headed directional flow.
3.05 PAINT
A. General Notes and Guidelines:
1. All color numbers and names herein refer to Tnemec master color card. Colors of specified equal Manufacturers may be substituted with approval of the Engineer.
2. Pipe lines, equipment, or other items which are not listed here shall be assigned a color by the Engineer and shall be treated as an integral part of the Contract.
3. When color coding is specified or directed by the Engineer, it shall consist of color code painting and identification of all exposed conduits, through lines and pipelines for the transport of gases, liquids, or semi-liquids including all accessories such as valves, insulated pipe coverings, fittings, junction boxes, bus bars, connectors and any operating accessories which are integral to a whole functional mechanical pipe and electrical conduit systems.4. The colors of the Finish Schedule shall be interpreted as follows:
COLORS TNEMEC # COLORS TNEMEC # White ...... AA90 Red ...... CC13 Yellow ...... BW56 Blue ...... BR18 Green ...... BU20 D. Blue ...... 2042 L.Green ...... AU52 M.Blue ...... 2041 D.Brown ...... AF12 L.Blue ...... 2040
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Tan ...... AF32 Aqua ...... AX42 D. Yellow ...... BX36 Inter. Orange ...... CB20 Ivory ...... AF82 Orange (Safety) ...... CA26 L. Gray ...... BG62 Bronze ...... BL09 D. Gray ...... BK33 Tank Blue ...... BB42 M. Gray ...... 2047
4. All moving parts, drive assemblies and covers for moving parts which are potential hazards shall be Safety Orange No. CA26.
5. All safety equipment shall be painted in accordance with OSHA standards.
6. All inline equipment and appurtenances not assigned another color shall be painted the same base color as the piping. The pipe system shall be painted with the pipe color up to but not including the flanges attached to pumps and mechanical equipment assigned another color. Tanks shall be painted the color of the piping system that they serve, unless the tank is fiberglass.
7. All conduit shall be painted to match its background surface.
8. Building surface colors shall be painted as scheduled in the Finish Schedule or as selected by the Engineer.
9. Control panels shall be factory finished.
3.06 INSPECTION AND TESTING
A. All materials and work shall be accessible and subject to inspection by the Engineer.
B. The completed work shall be inspected visually by the Engineer for skips, holidays, hiding, uniform color and appearance, and other imperfections. All defective work shall be corrected by the CONTRACTOR or applicator at no cost to the Owner.
C. Coating thickness on steel shall be determined in accordance with SSPC-PA-2. The number of readings will be a minimum of that stated in SSPC-PA-2.
D. Coating integrity for coatings in immersion areas or subjected to splash and spillage shall be determined in accordance with NACE RP0188-88 "Standard Recommended Practice for Discontinuity (Holiday) Testing of Protective Coatings" using the low voltage wet sponge test method. All holidays will be clearly marked for repair.
E. The Contractor shall furnish to the job site and use for coating inspection and make available to the Engineer the following test equipment:
1. Wet film thickness gauge.
2. Dry film thickness gauge (with certified thickness calibrator) equal to Mikrotest III, Elcometer Inspector III, or Positest.
3. Surface Temperature Gauge.
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4. Holiday Detector. Low voltage type such as Tinker & Rasor Model M-1, Series 9533.
5. SSPC VIS-1-67T Pictorial Surface Preparation Standard.
6. Keane-Tator Surface Comparator Number 372 or equal.
7. NBS Certified Coating Thickness Standards.
8. Sling Psychrometer.
9. Surface moisture metering device equal to Delmhors Model DB.
3.07 CLEANUP
A. The premises shall at all times be kept free from accumulation of waste material and rubbish caused by employees or work. At the completion of the painting remove all tools, scaffolding, surplus materials and all rubbish from and about the buildings and leave work "broom clean" unless more exactly specified.
B. Upon completion, remove all paint where it has been spilled, splashed, or splattered on all surfaces, including floors, fixtures, equipment, furniture, etc., leaving the work ready for inspection.
PAINT AND COLOR CODING SCHEDULE
Piping and Legend Color Bands
Chlorine Solution Yellow
Raw Wastewater Dark Brown
Compressed Air Green Red
Instrument Air Green
Blower Air Green Orange
Chlorine Gas Yellow
Drains Dark Grey Red
Reuse Washdown Water Grey Orange
Potable Cold Water Blue
Potable Hot Water Blue Red
Other piping to match existing or as directed by the Engineer.
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Equipment and Building Color
Exterior Equipment; Valves; Gates; etc. Brown
Interior Equipment and Pumps Dark Brown (including factory finished)
Structural Steel (Exterior) Bronze
Ceiling White
Interior Air Handling and Ventilation Equipment White
Valve and Gate Operators Ivory
Electrical Conduit and Junction Boxes Match Surface Mounted
END OF SECTION
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SECTION 11208
SUBMERSIBLE SEWEAGE PUMPS
PART 1 GENERAL
1.1 SUMMARY
A. Section Includes: Requirements for furnishing and installing submersible sewage pumping units, together with base elbows, guide rail systems, variable frequency drives, liquid level controls, control panels, access covers and all appurtenances necessary for a complete installation.
B. Related Work Specified in Other Sections Includes:
1. Section 09900 - Painting
1.2 REFERENCES
A. Codes and standards referred to in this section are:
1. ASTM A 48 - Specification for Grey Iron Castings 2. Hydraulic Institute Standards 3. IEEE 82 - Test Procedure for Impulse Voltage Tests on Insulated Conductors 4. NEC - National Electric Code 5. AFBMA 9 - Load Ratings and Fatigue Life for Ball Bearings 6. AFBMA 10 - Specifications for Metal Balls
1.3 SYSTEM DESCRIPTION
A. General: Provide pumps of the vertical, centrifugal, heavy duty, nonclog, close coupled, submersible type, each driven by submersible electric motor mounted as an integral part of the pump. Design the pumping units to pump raw unscreened sewage. Arrange the pumping equipment guide rails and base elbow for installation in the spaces shown without appreciable revision of the piping or structure. Design the pumping units for continuous and intermittent duty with ten starts per hour per pump.
B. Operating Conditions: Provide pumps to operate at the capacities and heads and over the range of operating conditions specified without overloading, cavitation, and vibration. Furnish the pumps in accordance with the following requirements:
Item Requirements 5000-79695 11208-1 Florida Governmental Utilities Authority Waterway Estates Interconnect 60% Submittal
Pump 1 Pump 2 Capacity at rating point, gpm 2800 2800 Total head at rating point, feet 70 70 Overall efficiency, wire to water, at 72% 72% rating point, minimum, percent Shutoff head, feet Maximum 100 100 Minimum 45 45 Capacity at secondary rating point, 3750 3750 minimum, gpm Total head at secondary rating point, feet 55 55 Overall efficiency, wire to water, at 70 70 secondary head, minimum, percent Capacity at reduced speed rating point, 1400 1400 gpm Total head at reduced speed rating point, 16 16 feet Diameter of sphere that will pass 3 3 through pump, minimum, inches Pump discharge diameter, minimum, 10 10 inches Pump speed, maximum, rpm 1185 1185 Low water elevation for continuous -0.5 -0.5 operation, feet Wet well floor elevation, feet -4.0 -4.0 Motor horsepower, hp 70 70 Motor efficiency at full load, minimum, 91% 91% Percent Motor power factor at full load, minimum Locked rotor kVa/hp, maximum, (Motor) (NEMA) code letter B
C. Pump Curve: Design each pump to have a continuously rising characteristic curve from the rating point to shutoff which passes through the rating point, and which meets or exceeds the specified heads and capacities, all within the Hydraulic Institute tolerances.
D. Provide submersible units capable of sustaining full reverse runaway speed without damage.
1.4 SUBMITTALS
A. General: Provide all submittals, including the following, as specified in Division 1.
B. Shop Drawings: Submit working drawings, including arrangement and erection drawings of the equipment and equipment operating characteristics. Include the following:
a. Pump performance curves. Draw the curves for the specified conditions including those at reduced speed. Plot head, input kilowatts, and overall efficiency, as a function of capacity from zero to maximum capacity. 5000-79695 11208-2 Florida Governmental Utilities Authority Waterway Estates Interconnect 60% Submittal
b. General arrangement drawing of pumping unit, base elbow and guide rail system. Include equipment weight and anchor methods and materials.
c. Cross section drawing of pumping unit.
d. Parts list with materials of construction identified.
e. Motor performance characteristics.
f. Spare parts list.
g. Painting procedure.
C. Quality Control Submittals: Submit 6 certified copies of the Shop Test results.
D. Operation and Maintenance: Submit the Operation and Maintenance manuals for the pumping equipment.
1.5 PUMP WARRANTY
A. The pump manufacturer shall warrant the pumps being supplied against defects in workmanship and materials for a period of five (5) years under normal use, operation and service. In addition, the manufacturer shall replace certain parts which shall become defective through normal use and wear on a progressive schedule of cost for a period of five (5) years; parts included are the seal, impeller, pump housing, wear ring, and bearings. The warranty shall be in published form and apply to all similar units.
1.6 QUALITY ASSURANCE
A. Qualifications: Provide pumping equipment produced by a manufacturer who regularly engages in the design, manufacture, assembly and production of submersible sewage pumping equipment of the size and type as specified for not less than five years.
B. Regulatory Requirements: Rate the motor unit, and wet well wiring for service in hazardous Class 1, Division 1 locations.
1.7 DELIVERY, STORAGE AND HANDLING
A. Deliver, store and handle all products and materials as specified in Division 1.
1.8 PARTS
A. Special Tools: Furnish a complete set of special wrenches, spanners, eyebolts and other special tools sufficient to completely dismantle and reassemble each kind and size of pumping unit. Provide tools of forged steel, case hardened, and full finished. Furnish the sets with a metal tool case with a handle and provision for padlocking.
PART 2 PRODUCTS 5000-79695 11208-3 Florida Governmental Utilities Authority Waterway Estates Interconnect 60% Submittal
2.1 MANUFACTURERS
A. Acceptable manufacturers are listed below. 1 . Flygt Corporation 2. ABS Pumps, Inc.
2.2 GENERAL CONSTRUCTION
A. Materials: Provide stainless steel fasteners, bolts, nuts and washers where exposed to the pumped liquid.
B. Component Joints: Provide machined metal-to-metal joints on component parts that are assembled together. Fit with an 'D"ring seal where watertight joints are required. Arrange the "O"ring seal for automatic compression and sealing without adjustment or bolt torquing procedures. Do not use flat gaskets or sealing compounds to obtain watertight joints. Furnish machined rabbet fits on component joints as required to provide automatic alignment of rotating parts.
2.3 CASING
A. General: Provide pump casing of the centrifugal single volute, centerline discharge type. Do not use diffusion vanes.
C. Materials: Construct pump casing of ASTM A48, Class 30B or 35B cast iron.
D. Wear Ring: Construct renewable wear rings of stainless steel.
2.4 IMPELLER
A. General: Design impeller of the enclosed nonclog type. Provide pump-out vanes or a back ring, arranged with minimum clearances so as to preclude solids and stringy material from damaging the mechanical seal, on the back of the impeller.
B. Materials: Construct the impeller of cast iron ASTM A48, Class 30B or 358.
C. Balance: Dynamically balance the impellers.
D. Wear Ring: Construct renewable impeller wear ring of brass.
E. Assembly: Secure the impeller to the shaft with a stainless steel key and lock nut in such a way that it cannot unscrew or become loosened due to rotation in either direction.
2.5 OIL CHAMBER
A. General: Provide an oil chamber to function as a buffer between the pumped liquid in the casing and the motor. Arrange the oil chamber to accommodate thermal expansion of the oil. Furnish an oil chamber drain plug that is accessible from outside the pump unit and permits changing oil without dismantling pump components.
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B. Materials: Construct the oil chamber of ASTM A48 cast iron, Class 30B or 35B.
2.6 MECHANICAL SEAL
A. Design: Provide each pump with double tandem mechanical seals. Design the upper seal unit, between the oil chamber and motor housing, with one stationary tungsten carbide ring and one positively driven rotating carbon ring. Design the lower seal unit, between the pump casing and oil chamber, with one stationary ring and one positively driven rotating ring. Furnish these rings made of tungsten-carbide. Use type 316 stainless steel for metal parts. Protect the spring element of the lower seal from solids contained in the pumped liquid. Do not rely upon the pumped liquid for lubrication. No seal damage is to result from operating the pumping unit out of its liquid environment. Conventional double mechanical seals with a single or double constant differential pressure to effect sealing and subject to opening and penetration by pumping forces will not be acceptable.
2.7 MOTOR
A. General: Provide submersible pump motor of 460-volt, 3-phase, 60-hertz as specified in Section 16155.
B. Ratings: Design the motor to have suitable output torque and speed characteristic to start and operate the pump over the range of specified conditions. For constant speed pumping units do not exceed the nameplate horsepower rating under maximum load conditions. For pumping units operated from variable frequency drives, provide a motor nameplate horsepower rating at least 15 percent greater than the maximum load conditions. Base the nameplate horsepower rating on an 80 degrees C temperature rise above an ambient temperature of 40 degrees C. Design the motor for continuous load operation and continuous on-off cycling of ten starts per hour minimum without exceeding the 80 degree C temperature rise.
C. Insulation: Provide the motor with a minimum of NEMA Class F (155 degrees C) moisture resistant insulation. Construct stator coils with NEMA Class F insulated winding wire. Apply impregnation resin to stator assembly in three dip and bake steps.
D. Stator Housing: Provide the motor with an ASTM A48, Class 30B or 35B cast iron stator housing. For motors that employ cooling water jackets, design the water jacket passages to preclude clogging by solids contained in the pumped liquid.
E. Cables: Provide the motor cable entry with a mechanical locking ring or compression type cord grip to protect the cable jacket from being pulled out of the motor. Do not use epoxy for this purpose. Arrange the cable entry so as to provide a watertight seal with a terminal board and terminations next to the motor. Isolate the cable entry leads from the intemal motor leads to prevent entry of water into the motor chamber by leakage or wicking. Provide cables suitable for submersible pump application and conforming to NEC specifications for cable sizing. Provide permanent label on cables.
F. Shaft 1. Design: Provide a one piece, fully machined pump and motor shaft. Design the 5000-79695 11208-5 Florida Governmental Utilities Authority Waterway Estates Interconnect 60% Submittal
shaft to limit shaft deflection under maximum pumping load to .002 inches at the lower mechanical seal face and to obtain a rotating assembly first critical speed of not less than 150 percent of the rated speed.
2. Material: Provide shafts of either carbon steel or stainless steel. Protect carbon steel shafts from exposure to the pumped liquid by employing a stainless steel sleeve or chrome plating.
G. Bearings
1. Design: Provide two anti-friction bearing assemblies. Design one assembly to carry only radial loads and to be free to float axially within the frame. Design the other assembly to carry both radial and axial loads and to be restrained from axial movement.
2. Bearing Life: Select bearings in accordance with AFBMA 9 and AFBMA 10, Load Ratings and Fatigue Life for Ball and Roller Bearings, to have a 20,000 hours minimum L10 bearing life at maximum pumping load that occurs under the specified operating conditions.
2.8 PROTECTION MONITORING SYSTEM
A. General: Provide each pumping unit with a monitoring system to protect critical machine functions during operation.
B. Motor Winding Temperature: Provide three thermoswitches, one per phase, to protect against overheating. Initiate an alarm and motor shutdown on high temperature.
C. Automatic Megger: All pumps 294 watt (30 HP) and larger shall be furnsihed and installed with one (1) completely enclosed solid state electronics module (automatic megger) to automatically monitor the motor winding resistance on each pump. Each automatic megger must have an individual disconnect terminal plug and manual shut off switch. Each automatic megger must have three (3) lights to indicate 10M ohm, 5 M ohm, and 1 M ohm resistance values. Power source to be 110 VAC fused at y.; amp. The D.C. test volt to be 500 to 700 volts. The output current to be limited to less than 1 micro amp. Must also have two (2) output circuits for external alarms. When the motor resistance drops to 1 M ohm, an alarm system must be activated by the internal circuit of the automatic megger. The automatic megger must monitor the motor resistance only when the motor is off. Each automatic megger must also include two (2) switches for manual testing. The automatic megger is to be manufactured by Automeg, Inc., or approved equal.
D. Sensor Monitoring Device: Provide a monitoring device or devices designed to be compatible with the sensors and motor controls. Locate monitoring devices in control panel.
2.9 GUIDE RAIL SYSTEM AND BASE ELBOW
A. Design: Provide each pump with a base elbow and guide rail system. Design the guide rail system to permit installation and removal of the pump from its base elbow discharge connection without requiring personnel to enter the wet well. 5000-79695 11208-6 Florida Governmental Utilities Authority Waterway Estates Interconnect 60% Submittal
B. Guide Rail System: Provide a guide bracket which is an integral part of the pump casing and permits sliding the pumping unit, along two unthreaded 316 stainless steel guide rails. Provide the guide rails of 316 stainless steel pipe connected to the base elbow at the bottom. Support the guide rails at Intermediate locations and at the top with stainless steel brackets bolted to the wall of the wet well or concrete slab. Fit each pump with a 316 stainless steel cable of adequate length and strength to permit the raising and lowering of the pump for inspection and removal.
C. Base Elbow: Provide a cast iron base elbow arranged for automatic pump connection. Provide the pump casing with a machined discharge flange which, when the pump is lowered into the pumping position, will automatically align and mate with the plain-end of the base elbow. Design the discharge connection such that no motion other than vertical is required to seat the mating flange of the casing to the base elbow. Accomplish sealing of the pump connection by metal to metal contact or by a positive resilient seal of Buna-N attached to the pump casing discharge flange. Design the base elbow to support the weight of the pumping unit and prevent it from bearing directly on the wet well floor.
D. Mounting Accessories: Provide anchor bolts, nuts, washers, and accessories and other adapter equipment necessary for mounting the pumping equipment and appurtenances. Construct anchor bolts, nuts, washers, accessories and adaptor equipment of 316 stainless steel. Provide 3/8-inch minimum 316 stainless steel chain a minimum of 20 inches long attached to a minimum %-inch minimum 316 stainless steel wire rope which is to be hung on a 316 stainless steel rack at the top of the wet well.
2.10 OPERATION AND CONTROL
A. See Section 16160 for control panel requirements.
B. Each pumping station control system shall include a liquid level controller which shall sense the sewage level in the wet well and provide appropriate signals to the logic circuits to produce the required mode of operation for the pumping facilities. The standard level controls shall be five (5) non-mercury Rotofloats as manufactured by Anchor Scientific Inc. Long Lake, MN, or approved equal. At pump stations where there is a possibility of massive accumulation of floatables, oil and grease that may interfere with the proper operation of the floats, Lee County Utilities may required the installation of a bubbler type liquid level control system as manufactured by Digital Control Corporation or Lee County Utilities approved equal. All pump stations serving
commercial and industrial facilities will be required to have a bubbler type liquid level control system unless specifically approved by Lee County Utilities.
C. Any alternative levels sensing and control system must be approved by Lee County Utilities. The bubbler type liquid level control system and any alternative levels sensing and control system shall include a high and a low level floats as a back-up system. Capability shall be provided for manual start-stop control for all pumping units as well as the normal automatic control from the liquid level sensing and logic circuits. An automatic alternator shall change the starting sequence on each pump cycle. A high water level, non-loathing alarm system shall be provided. Each sewage pump 5000-79695 11208-7 Florida Governmental Utilities Authority Waterway Estates Interconnect 60% Submittal
shall be provided with an elapsed time meter to indicate pump running time. The submersible station controls shall be housed within an exterior panel, pole-mounted or free-standing enclosure. The panel will be of NEMA 4X, stainless steel, weather-tight construction with double dead front outer doors fitted with hoop and padlock master keyed to County standard. Each panel shall be equipped with a service lock out switch to lock out alarm signals to the Telemetry System.
D. The requirement for variable speed controlling of sewage pumps shall be considered for all large capacity pumps for major installations; and when the hydraulic conditions indicate the requirement. The requirement for variable speed pump controls shall receive prior review with Lee County Utilities. Should such system be directed, the facility shall be equal to existing Lee County Utilities variable speed control units, or as approved by Lee County Utilities.
PART 3 EXECUTION
3.1 INSTALLATION
A. Install all equipment in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1. Complete all wiring and piping and make all necessary adjustments to equipment to provide a complete operational pumping installation.
3.2 FIELD QUALITY CONTROL
A. Manufacturer's Field Services: Furnish the services of a qualified representative of the manufacturer to provide instruction on proper installation of the equipment, inspect the completed installation, make any necessary adjustments, participate in the startup of the equipment, participate in the field testing of the equipment and place the equipment in trouble-free operation, as specified in Division 1.
B. Tests: After installation of the pumping units, control equipment and all appurtenances, subject each unit to a field running test as specified in Division 1, under actual operating conditions. Perform the field tests in the presence of and as directed by the ENGINEER. Demonstrate that under all conditions of operation each unit:
1. Has not been damaged by transportation or installation.
2. Has been properly installed. 3. Has no mechanical defects.
4. Has been properly connected.
5. Is free of overheating of any parts.
6. Is free of overloading of any parts.
Test the pumps to demonstrate that the pumps and control system operate as specified. Promptly correct any defects in the equipment or failure to meet the 5000-79695 11208-8 Florida Governmental Utilities Authority Waterway Estates Interconnect 60% Submittal
requirements of the Specifications.
Conduct 24 hours of continuous operation test prior to acceptance.
3.3 CLEANING AND PAINTING
A. Paint as specified in Section 09900.
END OF SECTION
5000-79695 11208-9 Florida Governmental Utilities Authority Waterway Estates Interconnect 60% Submittal
SECTION 11258
BIOLOGICAL ODOR CONTROL SYSTEM EQUIPMENT
PART 1 GENERAL
1.01 SCOPE
A. The work specified herein shall include designing, furnishing and installing all equipment and materials necessary to provide Lee County Utilities with a completely operational Biological Odor Control System to include delivery .and placing of unit on prepared site (see site topographical image for prepared site location attached). The system shall be a completely packaged two-stage, biological absorption/adsorption system of UNITARY CONSTRUCTION. The awarded vendor shall be responsible for providing a complete Odor Control System that shall include, but not be limited to FRP or HDPE vessel, nozzles, two independent stages of inorganic treatment media, moisture controls, nutrient supply system, air supply fan, interconnecting ducting, and all necessary accessories to include providing all intake ducting from both station wet wells to odor control system, dampeners, expansion joints, duct supports, fasteners & gaskets for flanged duct connections, piping, valving and a basic installation drawing to include location of dampeners, piping location in wet well and all accessories on intake ducting which is to ensure odor control unit and accessories are installed in accordance with manufacturer of odor control system. A mandatory pre-bid meeting will be conducted (see details elsewhere in this quote package). Physical address of lift station is 806 South St., Fort Myers Beach, Florida 33931.
1.02 DESCRIPTION
A. Multi-Stage Package System: The awarded vendor shall furnish and install a complete "once- through two-stage", pre-piped, wired, and packaged UNITARY CONSTRUCTION odor control system including two integral treatment stages, exhaust fan, valves, fittings, ductwork, and all other equipment and accessories as specified to provide a complete and functioning system. The biological treatment stage shall utilize an inorganic media to facilitate absorption and adsorption of odor compounds. The polishing stage shall utilize a virgin activated carbon polishing media that shall be specifically designed to adsorb odorous compounds with the ability to support biological degradation of the compounds. The first stage shall operate with an independently controlled irrigation system to maintain optimum wetted conditions to support unique microbial growth for biological destruction of the odorous compounds and removal of toxic metabolites. Systems using any type of organic media and systems using a single inorganic media shall not be acceptable.
B. Design Basis The mechanical, structural, process and electrical design will be based on the enclosed specifications.
1.03 REFERENCE STANDARDS
A. PS 15-69: National Bureau of standards Voluntary Product Standard "Custom contact molded Reinforced Polyester Chemical Resistant Process Equipment".
B. ASTM 0-883: "Definition of Terms Relating to Plastics"
5000-79695 11258-1 Florida Governmental Utilities Authority Waterway Estates Interconnect 60% Submittal
C. ASTM D-2583: "Test for Indentation Hardness of Rigid Plastics by Means of Barcol Impressor."
D. ASTM 0-2563: "Recommended Practice for Classifying Visual Defects in Glass Reinforced Plastic Laminate Parts."
E. ASTM 0-4097-82: "Standard Specifications for Contact Molded Glass Fiber Reinforced Thermoset Resin Chemical Resistant Tanks."
1.04 QUALITY ASSURANCE
A. Manufacturer: The products furnished under this section shall be by a manufacturer who has been regularly engaged in the design and manufacture of the equipment and who has a minimum of 3 years experience in design, fabrication and testing of biological odor control systems. The odor control Manufacturer shall show evidence of at least five (5) similar 2- stage design installations in satisfactory operation in wastewater treatment plant facilities for at least 3 years; this shall be accomplished through references. In the space provided on Attachment A, please provide the requested contact information for your five (5) references. The odor control Manufacturer shall have used proposed biofiltration media for a minimum of 3 years. The Odor Control Manufacturer that submits a quotation shall arrange for a site visit to location with a similar system proposed and located within a day trip from Fort Myers, Florida and that has been in operation for a minimum of3 years. The travel cost(s) of the site visit(s) shall be the responsibility of Lee County Utilities.
B. Inspection and Testing Requirements: Lee County Utilities reserves the right to reject delivery of any or all pieces of equipment found, upon inspection, to have any or all of the following: blisters, chips, crazing, exposed glass, cracks burned areas, dry spots, foreign matter, surface porosity, sharp discontinuity or entrapped air at the surface of the laminate. Any item that does not satisfy the tolerances as below shall be rejected:
Defect Inside Surface Outside Surface Blister None Max. dimensions: ¼” diameter by 1/8” high; Max density; 1 per sq. ft.; Min. separation: 2” apart Chips None Max. dimension of break: ¼” and thickness no greater than 10% of wall thickness; Max. density: 1 per sq. ft. Crazing None Max length: ½”; Max. density: 5 per sq. ft.; Min. separation: 2” Cracks None None Exposed Glass None None Scratches None Max. length: 2”; Max. depth: 0.010” Max density; 2/sq. ft. Burned Areas None None Surface Porosity None None Foreign Matter None None Sharp Discontinuity None None Pits Max. 1/8 inches, dia. By 1/32 Max. 1/8” dia. By 1/16” deep, inches deep; Max: 10 per ft2 Max: 10 per sq. ft.
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Defect Inside Surface Outside Surface Dry Spot None 2 sq. in. per sq. ft. Entrapped Air None at the surface 1/16 inches 1/8” and 4 per sq. in. or 1/16” and 10 per square in. max and 10 per sq. in. within laminate
C. Lee County Utilities reserves the right to be present at the fabricators facility for visual inspection of equipment to be supplied.
D. Upon completion of the installation, each piece of equipment and each system shall be tested for satisfactory operation without excessive noise, vibration, overheating, etc. Compliance shall be based on the equipment manufacturer's specifications and all applicable costs and standards. All equipment must be adjusted and checked for misalignment, clearances, supports, and adherence to safety standards.
E. The awarded vendor and/or manufacturer shall be responsible for the successful startup and testing of each odor control facility. The awarded vendor and/or manufacturer shall provide all necessary facilities, manpower, tools, instrumentation, and laboratory testing services required during this phase of the work.
1.05 REQUIRED SUBMITTALS
Any submittals requested should be returned with the quote response. This information may be accepted after opening, but no later than 10 calendar days after request.
A. The Manufacturer should submit complete Shop Drawings for the System, together with all piping, ductwork, valves, and control along with a basic installation drawing for the intake ducting which shall include recommended location for all ducting components for review by Lee County Utilities.
B. Shop Drawings: The Manufacturer shall submit the following information for approval before equipment is fabricated:
1. Drawings of system showing assemblies, arrangements, piping, electrical, mounting details, equipment outline dimensions, fitting size and location, motor data, operating weights of all equipment and sufficient information to allow Lee County Utilities to check clearances, connections, and conformance with the specifications. 2. Materials of construction of all equipment 3. Manufacturer's catalog data, operating literature. Specifications, performance data, and calibration curves for exhaust fan and auxiliary components. 4. Complete instrumentation, control, logic and power wiring diagrams in sufficient detail to allow installation of the instrumentation, controls, and electrical components. 5. Manuals: Furnish manufacturer's installation, operation and maintenance manuals, bulletins, and spare parts lists. 6. Reference list demonstrating minimum qualifications as required in paragraph 1.4.A above. 7. A complete summary of operating cost shall be provided. At a minimum the following information shall be provided: • Annual electrical operating cost. Show calculations and use $0.06/kW-hr. • Media replacement cost. • Nutrient cost per year. 8. A copy of the performance guarantee and the warranty. 5000-79695 11258-3 Florida Governmental Utilities Authority Waterway Estates Interconnect 60% Submittal
9. It shall be the supplier's responsibility to carefully examine each item of the specifications. Failure to offer a complete quotation or failure to respond to each section of the technical specifications may cause the quotation to be rejected without further review as "non-responsive." 10. Provide information on service center as required by section 3.5.
1.06 MANUFACTURER'S SERVICES
A. The system manufacturer's representative shall be present at the job site for the following time period; travel time excluded: 1. Sixteen hours for inspection of the installation and training of County's staff in operation of the system. 2. Provide one trip for two days for these tasks.
PART 2 - PRODUCTS
2.01 GENERAL
A. The Vendor shall provide an odor control system specified which shall treat in a single pass the odorous air from the contaminated areas. The system shall be designed for continuous, automatic opemtion and also be capable of manual operation. Access manways shall be provided to allow access to the internals of the system. The system shall be designed to withstand a temperature up to 120°F. The multi-stage packaged FRP or HDPE system shall be of UNITARY CONSTRUCTION, as specified in Section 2.3. The module and all accessories shall be factory mounted, piped, and wired to the maximum extent possible. Basic design drawing of intake ducting from both 2263 & 2263A will be included which will require dampeners to allow for air flow adjustments between the two wet wells. All intake ducting and associated piping, valves & dampeners that will be needed will be provided by the manufacturer. The awarded vendor is responsible for delivery of odor control system and placing of system on prepared site.
2.02 DESIGN AND PERFORMANCE CRITERIA
A. Design and Performance Criteria: 1. Criteria: The system shall be capable of removing foul air at a rate no lower than the rate shown on the following table. The dimensions of the package odor control unit shall not exceed 15ft long x 8ft wide x 10 ft tall. 2. Foul air removed from the facility will have an average and peak concentration of hydrogen sulfide (fhS) and design air flow rate as listed in the following table:
Air Flow Rate, cfm Ave. Inlet H2S Conc. Peak H2S Conc. 200 cfm 30 ppm 100 ppm
3. System Performance: The odor control system shall demonstrate the following performance when operating under design flow conditions listed above.
OUTLET 0.1 ppm H2S
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2.03 MULTI-STAGE FRP or HDPE PACKAGED BIOLOGICAL ABSORPTION/ADSORPTION SYSTEM:
A. General: The gas treatment system shall be a TWO-STAGE, ONCE THROUGH BIOLOGICALLY ACTIVE ODOR REMOVAL SYSTEM OF UNITARY CONSTRUCTION, designed to remove minimum of 99% DH2S vapor in a single pass. The system shall consist of one biological gas conditioning/treatment stage and one gas polishing stage in series. The first stage shall facilitate biological destruction of odor compounds absorbed by the liquid in the system and adsorbed on the inorganic media. The biological section shall include a spray header to distribute liquid evenly over the media. The complete treatment vessel shall be fabricated of premium grade FRP or HDPE. 1. The first treatment stage shall contain in organic media specifically designed to Support biological growth for degradation of odor compounds. This stage shall provide absorption of odors from the air stream. The second polishing stage shall contain coal based virgin media specifically designed to. adsorb odor compounds and to. Support biological degradation of those compounds. This stage shall provide final removal of odors to the specified level. 2. The first stage of media shall be wetted with fresh potable or re-use make-up water. 3. The overall system size, including the fan, controls, and appurtenances shall not exceed 14ft long x 8ft wide x 10ft tall. Access man ways shall be provided to' allow access to the system internals. As a minimum, access manways shall be provided between the treatment stages. A portion of the system top shall be removable for access to the top of the second stage. 4. The system shall be included with all piping, valves, and internals. The material of construction of internals shall be as follows: Packing Media Support: HOPE and FRP Liquid Distributor: PVC Spray Nozzles: PVC/316 Stainless Steel 5. The system shall have all components pre-mounted and piped on the unitary constructed system. The system shall be shipped as a single piece.
B. Material of Construction: 1. The vessel and accessories shall be Contact molded manufactured in accordance with NBS PS 15-69, ASTM D 4097 for contact molding. Any material of construction other than FRP with premium grade resin or HDPE will not be allowed. 2. Resin used in the system liner shall be a premium, vinyl ester type such as Hetron 922 by Ashland Chemicals, Derakane 411 by Dow Chemical, Vipel F010 by AOC, or approved equal. 3. Reinforcement: Glass fiber reinforcement used shall be commercial grade corrosion resistance borosilicate glass. • All glass fiber reinforcement shall be Type E electrical grade. • Mat shall be Type "E" (electrical grade) glass, I 112 oz. per sq. ft with a nominal fiber length of 1.25 ± 0.25 inches, with a silane finish and styrene soluble binder. • Continuous glass roving, used in chopper gun spray-up applications shall be type "E" grade with chrome or silane coupling agent • Alternate layers of mat and woven roving used for reinforcement. 4. Miscellaneous: • Stainless Steel: Unless otherwise specified, all fasteners, and metal attachments, such as anchors, brackets etc shall be ANSI 3 I6SS. • Gaskets: Unless otherwise specified, all gaskets shall be EPDM.
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C. Fabrication: 1. General: Fabrication shall be in accordance with NBS PS 15-69, ASTM D 3299 and ASTM D-4097. All non molded surfaces shall be coated with resin incorporating paraffin to facilitate a full cure of the surface. All cut edges, bolt holes, secondary bonds shall be sealed with a resin coat prior to the final paraffinated resin coat. All voids to be filled with a resin paste. 2. Corrosion Liner: The interior corrosion layer shall consist of two layers of 1 ½ oz. per sq. ft. chopped strand mat. If the application is by chopper gun spray up the glass fiber shall be 112 to 2 in length. The total corrosion liner thickness shall be a minimum of 100 mils and have a resin to glass ratio of 80/20. All edges of reinforcement to be lapped a minimum of one inch. . 3. Structural Laminate; Structural .laminates shall consist of alternating layers of 1- ½ oz. per sq. ft mat or chopped glass and 24 oz per sq. yard woven roving applied to reach a designed thickness. Actual laminate sequences shall be per the laminate tables shown on fabrication drawings. The exterior surface shall be relatively smooth and shall have no glass fibers exposed. The exterior shall be surface coated with gel coat containing ultra violet light inhibitors.
D. Accessories; Air inlet, air outlet, spray headers, baffles, media support, drain and all connections shown on the drawings shall be provided by the manufacturer. Tie down lugs shall be integrally molded into the wails of the vessel. All external bolts shall be 3 I6SS and designed for the specified loads. Interior fasteners shall be of corrosion resistant materials such as HDPE, PVC or FRP.
E. Neoprene Pad: A ¼” thick, 60 durometer neoprene rubber sheet shall be provided and placed underneath the vessel during installation.
2.04 EXHAUST FAN
A. General. Fan shall be centrifugal design manufactured of FRP with a radial blade wheel. The wheel shall be statically and dynamically balanced. The fan inlet shall be slip type and the fan outlet shall have a flanged nozzle. The fan will be provided with a double lip type shaft seal.
B. Fan shall be supplied with a TEFC motor with 1.15 service factor suitable for three-phase, 60Hz, 240/480 volt service. The fan shall be direct driven. The motor shall be explosion proof.
C. Performance. The fan shall be tested and rated in accordance with AMCA and shall bear the AMCA seal. The fan shall be designed for the following specifications:
Exhaust Fan Design Requirements Air Flow Rate, cfm >200 S.P. up to System Inlet, in WC 2 Total Pressure Drop, in WC Maximum 6 Motor, HP Minimum 3
D. Fan shall be manufactured by New York Blower, Hartzell, or equal.
E. Fan shall be New York Blower, Hartzell or equal. The fan shall have an AMCA seal.
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A. The electrical control panel shall provide electrical control for the exhaust fan and water addition system. A 240/480 V AC, 3-phase power supply shall be supplied to the panel to power the system.
B. The control panel enclosure shall be of fiberglass construction, HDPE or 316 Stainless Steel and rated NEMA 3R with ventilation fan. The panel shall be mounted to the system assemhly and factory tested to full operation with all other components prior to shipment.
C. The panel shall have the following components or capabilities: 1. Fan switch (ON-OFF). 2. Fan VFD. 3. Push-to-test button for water valve. 4. Timer relay or PLC for on/off control of water valve. 5. Nutrient Pump (HAND-OFF-AUTO) 6. Two dry output contacts for remote system diagnostics via a SCADA system.
D. The water control cabinet shall be constructed from a NEMA 12 rated FRP, HDPE or Stainless Steel with all internal piping SCH 80 PVC. The cabinet shall be mounted to the system assembly. The cabinet shall contain the following components: 1. Pressure reducing valve. 2. Nutrient Pump 3. Irrigation solenoid or motorized ball valve 4. Irrigation system pressure gauge.
E. Water pressure regulator, solenoid valve, and rotameter or paddle wheel flowmeter shall be provided for control of water application rates. These components shall be mounted in the water control cabinet.
2.06 ACCESSORIES
A. Water Flow Control: If provided, the direct reading rotameter shall be a variable area type with a Teflon float, EPR "0" rings, and PVC fittings. The rotameter shall have a direct reading scale.
B. Water Distribution System. The first media stage shall be equipped with an independent water distribution system. The system shall be designed to irrigate the top of the first media bed with complete and even coverage via spray nozzles.
C. Nutrient Addition. A nutrient containment and metering system shall be provided with the system. Nutrients supplied as a coating to the support media shall not be allowed.
2.07 PIPING
A. All make-up water and drain. piping shall be SCH 80 PVC. The Contractor shall insulate and heat trace all external piping as required by climatic conditions.
2.08 NUTRIENT RESERVOIR
A. The Nutrient Reservoir shall be integrated into the system or mounted on system skid. Loose external tanks shall not be allowed. ' 5000-79695 11258-7 Florida Governmental Utilities Authority Waterway Estates Interconnect 60% Submittal
PART 3 - EXECUTION
3.01 SITE AND UTILITIES
A. The following utilities shall be provided at the site by Lee County Utilities and are not provided by the Manufacturer under these specifications. Site preparation, utility service, and installation of intake ducting. 1. Electrical- 240/480 V AC, 3-phase service. 2. Water Supply - a 3/4 inch water supply with backflow preventer are required. Water supply will be provide for a minimum of 40 psi continuous pressure at 8 GPM and a hardness not to exceed 200 mgfL as calcium carbonate. 3. Drain - a minimum 2 inch P.V.C. gravity drain to sewer with a barometric trap.
3.02 START-UP AND TRAINING
A. The services of a factory representative shall be provided as specified in Section 1,6 to insure proper installation and start-up of the system. The Manufacturer shall make any changes to the system that may be necessary to meet the specified performance under inlet conditions as specified,
3.03 OPERATION AND MAINTENANCE MANUALS
A. Six (6) manuals shall be submitted prior to final acceptance of the equipment.
3.04 WARRANTY
A. Manufacturer shall warrantee the whole system, both in material and workmanship for a period of one year from the day of beneficial occupancy. This period shall not extend beyond 18 months after delivery of equipment to job site.
END OF SECTION
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SECTION 13300
PROCESS INSTRUMENTATION AND CONTROLS - GENERAL PROVISIONS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The INSTRUMENTATION SYSTEM SUPPLIER (ISS) shall furnish all services and equipment defined herein and in other Specification sections as listed below under related work.
B. The ISS shall provide all materials, equipment, labor, and services required to achieve a fully configured, integrated, and operational system. The ISS shall design and coordinate the instrument and control system for proper operation with related equipment and materials furnished by other suppliers under other sections of these Specifications and with related existing equipment.
C. The ISS shall provide the following for the Intermediate Pump Station and Lift Station LS-01:
1. ISS shall provide all Instrumentation field equipment specified under Specification Section 13315. These instruments shall interface with the respective pump station control panel.
2. ISS shall provide a control panel for each pump station, which will include programmable logic controller (PLC) and remote telemetry unit (RTU) hardware for control of the pumps and monitoring of local instrumentation, and transmission to the Lee County Utilities Southwest Reclaimed Water Plant. ISS shall also provide radio survey services and provide an antenna for each remote site. ISS shall provide all software necessary to program PLC and RTU. Digital hardware is specified under Section 13310.
3. ISS shall provide all new and modified software, programming, configuration, integration, and graphics as specified herein and shown on Drawings, in the local pump station control panels and in the water plant existing SCADA system. Software standards shall be as specified under Section 13305 and per existing County standards.
D. Auxiliary and accessory devices necessary for system operation or performance, such as transducers or relays to interface with existing equipment or equipment provided by other ISS’ under other Sections of these Specifications, shall be included whether they are shown on the instrument drawings or not.
E. Substitutions on functions or type of equipment specified will not be acceptable. In order to insure the interchangeability of parts, the maintenance of quality, the ease of interfacing between the various subsystems, and the establishment of minimums with regard to ranges and accuracy, strict compliance with the above requirements shall be maintained. In order to insure compatibility between all equipment, it shall be the responsibility of the ISS to coordinate all interface requirements with mechanical and electrical ISSs and furnish any signal isolation devices that might be required.
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F. Equipment shall be fabricated, assembled, installed, and placed in proper operating condition in full conformity with detail Drawings, specifications, engineering data, instructions and recommendations of the equipment manufacturer as approved by the Engineer.
G. To facilitate the Owner’s and/or Engineer’s future operation and maintenance, products shall be of the same major instrumentation manufacturer, with panel mounted devices of the same type and model as far as possible.
H. All equipment removed in the course of this Work shall become the property of the Owner to salvage or dispose of offsite.
I. All equipment and installations shall satisfy applicable Federal, State, and local codes.
J. Supplementing this Section, the Drawings and the related Specification sections provide additional details showing panel elevations, instrument device schedules, functional requirements of the system, and interaction with other equipment.
K. The ISS shall coordinate and schedule all required testing and training with the Contractor, Owner, and Engineer.
1.02 RELATED WORK
A. The ISS shall furnish all materials, labor, and services specified in the following Specification Sections as required to ensure a single, coordinated system is supplied:
1. Section 13305 – Application Engineering Services
2. Section 13310 – Digital Hardware, Software, and Telemetry
3. Section 13315 – Field Instrumentation
4. Section 13325 – Control Panels and Panel Mounted Equipment
B. Divisions requiring coordination shall include, but not be limited to the following:
1. Division 0 – Bidding and Contract Requirements
2. Division 1 – General Requirements
3. Division 11 – Equipment
4. Division 13 – Instrumentation
5. Division 15 – HVAC and Plumbing
6. Division 16 - Electrical
1.03 SUBMITTALS
A. Submit shop drawings in accordance with Section 01300. These shop Drawings shall fully demonstrate that the equipment and services to be furnished will comply with the provisions
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of these specifications and shall provide a true and complete record of the equipment as manufactured and delivered. Submittals shall be bound in separate three-ring binders, with an index and sectional dividers, with all Drawings reduced to a maximum size of 11-in by 17-in for inclusion within the binder. Separate submittals shall be made as follows:
1. Project plan. Note: The project plan shall be submitted and approved before any further submittals will be accepted.
2. Testing
3. Training
4. Spares and Test Equipment
5. Process instrumentation and controls
6. Digital system hardware
7. Digital system software
8. Digital specific system software applications
9. Operational and Maintenance (O&M) Manuals
B. Project Plan
1. It shall provide an overview of the proposed system including system architecture diagrams, the approach to work, the proposed work schedule indicating milestones and potential meetings, project personnel and organization, details of factory testing and field testing, details of training programs, and a paragraph by paragraph review of the specifications indicating any proposed deviations. The schedule shall illustrate all major project milestones including the following:
2. Schedule for all subsequent project submittals.
3. Tentative dates for all project design review meetings.
4. Schedule of manufacture and staging of all instrumentation and control system equipment.
5. Schedule for shipment of all instrument and control system equipment all peripheral devices.
6. Schedule for equipment start up.
7. Schedule for field acceptance test.
8. Schedule for all training.
9. The project plan must be submitted and approved before any future submittals are made.
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C. Testing Submittals
1. Test Plan
a. A test plan shall be submitted after all the submittals have been approved by the Engineer. The test plan shall demonstrate that the ISS has designed and configured a system that meets the design specifications. The test plan shall be submitted prior to the preparation of the detailed test procedures and submit outlines of the specific proposed tests. Submittals shall include examples of the proposed forms and checklists.
b. The test plan should include the following as a minimum:
1) A Bill of Materials (BOM) listing control system components
2) System hardware summary
3) A testing schedule describing the specific tasks to be performed and the time allotted for each task
4) Communications tests from the TCU to the SCADA nodes for discrete and analog I/O data transfer
5) 100 percent (100%) I/O point test including all spare points
2. Test Procedures
a. Preliminary test procedure submittals: Prior to the preparation of the detailed test procedures, submit outlines of the specific proposed tests. Submittals shall include examples of the proposed forms and checklists.
b. The test procedures shall be submitted after the preliminary test procedure submittals have been reviewed by the Owner and Engineer and returned stamped either "approved" or "approved as noted, confirm.” The submittal shall document the proposed procedures to be followed during the test. Procedures shall include test descriptions, forms, and checklists to be used to control and document the required tests. Testing may not be started until all Testing Submittals have been approved.
c. For Test Documentation submit a copy of the signed off test procedures upon completion of each required test.
D. Training Plan Submittals
1. Preliminary training plan submittal:
a. Within 120 days of Contract award to the Contractor, submit an overview of the proposed training plan. This overview shall include, for each course proposed:
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1) An overview of the training plan explaining why specific courses are proposed.
2) Course title and objectives.
3) Prerequisite training and experience of attendees.
4) Recommended types of attendees.
5) Course Content - A topical outline.
6) Course Duration.
7) Course Location - Training center or jobsite.
8) Course Format - Lecture, laboratory demonstration, etc.
b. The Owner and/or Engineer will review the preliminary training plan submittal with the Owner and/or Engineer.
2. Training Plan Submittal:
a. Upon receipt of the Owner’s and/or Engineer’s comments on the preliminary training plan, submit the specific proposed training plan. The training plan shall include:
1) Definitions of each course.
2) Specific course attendance.
3) Schedule of training courses including dates, duration, and locations of each class.
4) Resumes of the instructors who will actually implement the plan.
E. Spares, Expendables, and Test Equipment Lists Submittal
1. This submittal shall include for each subsystem:
a. A list of, and descriptive literature for, spares, expendables, and test equipment as specified for each Instrumentation Section (Section 13310, 13315, 13325).
b. A separate list of, and descriptive literature for, additional spares, expendables, and test equipment recommended by the ISS.
c. Unit and total costs for the additional spare items recommended for each subsystem.
d. Provide storage instructions for all spare parts.
e. Any specialty software or hardware tools used during configuration of the project. Note: These specialty tools must be turned over to the Owner.
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F. Process Instrumentation and Controls
1. This submittal shall provide complete documentation of all field instruments, control panels, and other instrument and control equipment not specified to be submitted elsewhere.
a. Provide data sheets for each component listing all model numbers, optional, and ancillary devices that are being provided.
b. The data sheets shall be provided with an index and proper identification and cross referencing. They shall include but not be limited to the following information.
1) Plant Equipment Number and ISA tag number per the Loop Diagrams.
2) Product (item) name used herein and on the Contract Drawings.
3) Manufacturer’s complete model number.
4) Location of the device.
5) Input - output characteristics.
6) Range, size, and graduations.
7) Physical size with dimensions, enclosure NEMA classification and mounting details.
8) Materials of construction of all components.
9) Instrument or control device sizing calculations where applicable.
10) Certified calibration data on all flow metering devices.
c. Provide equipment specification sheets which shall fully describe the device, the intended function, how it operates and its physical environmental and performance characteristics. Each data sheet shall have appropriate cross references to loop or equipment identification tags. As a minimum the specification sheets shall include the following:
1) Dimension, rigid-clearances.
2) Mounting or installation details.
3) Connection.
4) Electrical power or air requirements.
5) Materials of construction.
6) Environmental characteristics.
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7) Performance characteristics.
d. Provide detailed loop diagrams on a single 11-in by 17-in or 8.5-in by 11-in sheet for each monitoring or control loop. The loop diagram shall show all components of the loop both analog, digital, and discrete including all relays, switches, dropping resistors, etc. which are being provided for proper operation. Loop numbers used shall correspond to the loop numbers indicated in the contract documents. The format shall be the Instrument Society of America, Standard for Instrument Loop Diagrams, ISA 5.4 plus the following requirements:
1) On each diagram present a tabular summary of (1) the output capability of the transmitting instrument, (2) the input impedance of each receiving instrument, (3) an estimate of the loop wiring impedance based on wire sizes and approximate length used, (4) the total loop impedance, (5) reserve output capacity.
2) Show all interconnecting wiring between equipment, panels, terminal junction boxes and field mounted components. The diagrams shall show all components and panel terminal board identification numbers and all wire numbers. This diagram shall include all intermediate terminations between field elements and panels (e.g. terminal junction boxes). The diagrams shall be coordinated with the electrical ISS and shall bear his/her mark showing this has been done.
3) Show location of all devices.
4) Show instrument description showing type, manufacturer, model number, range, setpoints, and operation (e.g. fail open, open on energization, normally closed, etc.) as applicable.
5) Show all instrument loop power or instrument air requirements back to termination on terminal block or bulkhead, fuse block (including fuse size), etc., as applicable.
6) Show all grounding points within cabinets and panels and identify the connection point of individual components.
7) Show all programming functions and operations.
e. The submittal shall also contain all planning information, site preparation instructions, grounding and bonding procedures, cabling diagrams, plug identifications, safety precautions or guards, and equipment layouts in order to enable the Contractor to proceed with the detailed site preparation for all equipment.
G. Digital System Hardware (TCU, etc.)
1. General
a. This submittal shall provide complete documentation of the proposed hardware (TCU, communication equipment, cables, etc.). A complete Bill of Materials (BOM)
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listing all digital hardware equipment shall be provided.
b. The submittal shall include the following:
2. System Block Diagram
a. A complete system block diagram showing in schematic form, the interconnections between major hardware components such as; panels and field equipment, and off- site telemetry, power supplies, consoles, computer and peripheral devices, telemetry equipment, local digital processors and like equipment and uninterruptible power supplies (UPS). The block diagram shall reflect the total integration of all digital devices in the system and shall reflect any operator interface locations. All components shall be clearly identified with appropriate cross references to the location of each.
b. The diagram shall reference all interconnecting cabling requirements for digital components of the system including any data communication links.
3. Data Sheets
a. Data sheet for each hardware component listing all model numbers, optional, auxiliary and ancillary devices that are being provided.
b. The data sheets shall be provided with an index and proper identification and cross referencing. They shall include but not be limited to the following information.
1) Plant Equipment Number and ISA tag number per the Loop Diagrams (as applicable).
2) Product (item) name used herein and on the Contract Drawings.
3) Manufacturer’s complete model number.
4) Location of the device.
5) Input/output characteristics.
6) Range, size, and graduations.
7) Physical size with dimensions, enclosure NEMA classification and mounting details.
8) Materials of construction of all components.
9) Power supply device sizing calculations where applicable.
4. System Input/Output List:
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a. The Digital System Hardware submittal shall contain a complete system Input/Output (I/O) list for equipment connected to the control system under this Contract.
b. The ISS shall submit the I/O list in a Microsoft ExcelTM readable electronic file on CD and an 8-1/2 inch by 11-inch paper hard copy. The hard copy list shall be sorted first by ISA tag name and second by I/O type (i.e., AI, AO, DI, DO, PI, PO, etc.).
c. The I/O list shall follow the ISA numbering and labeling as far as possible. The list shall contain, as a minimum, the following for each active point and spare point:
1) Operator Interface Panel Tag List
a) Tag name
b) Type of I/O (i.e., DI, DO, AI or AO)
c) I/O point address (TCU name/address and point address)
d) Point name (or “SPARE”)
e) Point description
f) High/Low range and engineering units
g) Alarm limits
h) Relay normal status contact configuration
i) I/O terminal point physical location (panel name, rack, slot etc.)
j) 2-wire or 4-wire instrument.
2) TCU I/O List
a) Tag name
b) Type of I/O (i.e., DI, DO, AI or AO)
c) I/O terminal point physical location (panel name, rack, slot, etc.)
d) I/O point address (addresses to communicate with workstation and field devices)
e) Point name (or “SPARE”)
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f) Point description
g) Range and engineering units
h) Alarm limits
i) Relay normal status contact configuration
j) 2-wire or 4-wire instrument
d. Detailed drawings covering control panels, consoles and/or enclosures which shall include:
1) Cabinet assembly and layout Drawings to scale. These shall include both front and rear layouts.
2) Fabrication and painting specifications.
3) Color selection samples for selection by the Engineer.
4) Panel wiring diagrams showing all power connections to equipment within and on the enclosure, combined panel power draw requirements (volts, amps), breaker sizes, fuse sizes, and grounding. This wiring diagram shall be in ladder logic format and shall contain field termination details.. Coordinate with the electrical contractor to show all wire numbers and terminal block designations.
e. The Digital System Hardware submittal shall also contain all planning information, site preparation instructions, grounding and bonding procedures, cabling diagrams, plug identifications, safety precautions or guards, and equipment layouts in order to enable the Contractor to proceed with the detailed site preparation for all equipment.
f. Refer to section 13310 for additional submittal requirements.
g. Detail drawings to include the installation details of the antennal tower assembly, DFS drawing DFS-00355-008-01. Refer to section 13310, paragraph 2.03 for additional submittal requirements.
H. Digital System Software
1. The Software Functional Design submittal shall provide a complete description of the system on a functional level. The software shall be organized into functional subsystems. The intent of the Software Functional Design submittal shall be to describe, in detail, what functions are to be performed by each subsystem. It is not the intent of this documentation to describe the individual programs that support these functions.
2. The Software Functional Design submittal shall include, but not be limited to, the following items for each subsystem:
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a. Subsystem Abstract - A brief overview of the subsystem which shall describe its major functions.
b. Technical Description - A description of all the functions to be performed by the subsystem. This description shall indicate how the functions work from a user's standpoint.
c. Subsystem Structure - A diagram of the overall subsystem indicating major modules, data structures, and data flow. It shall also be defined whether the function is performed in the central system, a remote unit or both (where applicable).
d. Interface Structure - A diagram and/or description of the manner in which the subsystem interfaces with other subsystems.
e. Man-Machine Interface Consideration - A detailed description of all interface between the system and the operator shall be provided. All related CRT formats shall be shown.
f. Initialization Considerations - A description of the impact of power fail or system failover type restarts upon the subsystem shall be described.
3. The Software Functional Design Documentation shall also include a functional description of all support software as described in this Specification. As with the previous subsystems, this Software Functional Design submittal shall describe what functions are performed by each software support subsystem. This documentation shall describe what functional subsystems and data bases are affected by each support software subsystems.
4. This software submittal shall not cover the detailed control algorithms or process graphic displays. These shall be included in a subsequent submittal after the ISS has met with the Owner and/or Engineer and developed the specifics of these for pump station.
I. Specific Digital System Applications
1. This submittal shall cover the specific pump station control schemes as well as the details of the pump station reports and process graphic displays that the ISS has previously developed through meetings with the Owner and/or Engineer.
2. Any functional part of any loop that is implemented in software may either be shown on the same loop connection diagram or on a separate supplemental "loop software diagram". In either case, software diagramming shall be provided for each loop included herein. The software diagramming and the actual program shall be cross referenced and well annotated.
3. Symbology for software diagramming shall utilize one of the following methods. (Note this may or may not be the actual programming language used):
a. Ladder Diagram Format - This method may be used for programmable controllers only. The use of ladder diagrams to show logic in computer or microprocessors that cannot be programmed in ladder logic is not acceptable. Ladder diagram formats which depict analog control functions or which utilize subroutines, special
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programming control blocks, etc, shall be further described utilizing one of the following formats (formats b thru e) as is applicable.
b. Flow Chart Format - This method shall utilize symbology and conventions set forth in ANSI X3.5.
c. Binary Logic Format - This method shall utilize the symbology and conventions set forth in ISA Standard 5.2. (Latest Edition).
d. Structured Logic Format - This method shall utilize structured logic statements; if/and, and/or, etc.
e. Graphic Symbolic Representation Format - Symbolic representation of functions of digital systems shall be as set forth in ISA Standard 5.3.
4. Included with each diagram shall be:
a. Brief description of the Control Function.
b. Listing of all scanned inputs to the control function.
c. A short narrative of the control strategy.
d. Any assumptions made in developing the program.
e. Listing of all outputs (i.e., AO, DO) from the control function.
f. Listing of all operator inputs/outputs to and from the control function. Any special CRT displays related to the function shall be illustrated. A description of the operation of any panels shall be described as it relates to the control function.
g. Failure contingencies shall be described in detail.
h. Cross references to appropriate loop drawings and other programs.
5. The specifics of the logs, reports and process graphic displays shall be developed by the ISS in conjunction with the Owner and/or Engineer. The types and quantities are described in the Specification. The specifics of what shall appear on each and what calculations are required to support them shall be developed and submitted in final printed form for approval.
6. Refer to section 13310 for additional submittal requirements.
J. Operation and Maintenance (O & M) Manuals Submittal. Refer to paragraph 1.10 of this Section, and to Sections 01300 and 01730, for O&M Manual requirements.
1.04 REFERENCE STANDARDS
A. American Society for Testing and Materials (ASTM).
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1. ASTM A269 - Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service.
B. International Society of Automation (ISA)
1. ISA 5.1 – Instrumentation Symbols and Identification
2. ISA 5.2 - Binary Logic Diagrams for Process Operations
3. ISA 5.3 - Graphic Symbols for Distributed Control/Shared Display Instrumentation Logic and Computer Systems.
4. ISA 5.4 - Instrument Loop Diagrams
5. ISA 5.5 – Graphic symbols for Process Displays
C. American National Standards Institute (ANSI)
1. ANSI X3.5 - Flowchart Symbols and Their Usage in Information Processing
D. National Electrical Manufacturers Association (NEMA)
E. Where reference is made to one of the above Standards, the revision in effect at the time of bid opening shall apply.
1.05 QUALITY ASSURANCE
A. The ISS shall perform all work necessary to select, furnish, install, connect, and place into operation all hardware specified within this Division.
B. The ISS shall maintain a fully equipped office/production facility with full-time employees capable of fabricating, configuring, installing, calibrating, troubleshooting, and testing the system specified herein. Qualified repair personnel shall be available and capable of reaching the facility within a 24 hour period.
C. Actual installation of the system need not be performed by the ISS’s employees; however, the ISS shall be responsible for the on-site technical supervision of the installation.
D. The ISS shall furnish equipment which is the product of one manufacturer to the maximum practical extent. Where this is not practical, all equipment of a given type shall be the product of one manufacturer.
E. The ISS shall be one of the following parties:
1. xxx
1.06 DELIVERY, STORAGE AND HANDLING
A. Shipping Precautions
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1. After completion of shop assembly, factory test, and approval all equipment, cabinets, panels, and consoles shall be packed in protective crates and enclosed in heavy duty polyethylene envelopes or secured sheeting to provide complete protection from damage, dust and moisture. Dehumidifiers shall be placed inside the polyethylene coverings. The equipment shall then be skid-mounted for final transport. Lifting rings shall be provided for moving without removing protective covering. Boxed weights shall be shown on shipping tags together with instructions for unloading, transporting, storing and handling at job site.
2. Special instructions for proper field handling, storage and installation required by the manufacturer for proper protection, shall be securely attached to the packaging for each piece of equipment prior to shipment. The instructions shall be stored in resealable plastic bags or other acceptable means of protection.
3. All equipment supplied under Sections 13310, 13315, and 13325 shall be shipped to the job site via dedicated air ride van.
B. Identification
1. Each component shall be tagged to identify its location, tag number and function in the system. Identification shall be prominently displayed on the outside of the package.
2. A permanent stainless steel or other non-corrosive material tag firmly attached and permanently and indelibly marked with the instrument tag number, as given in the tabulation, shall be provided on each piece of equipment supplied under this Section.
C. Storage
1. Equipment shall not be stored out-of-doors. Equipment shall be stored in dry permanent shelters including in-line equipment, and shall be adequately protected against mechanical injury. If any apparatus has been damaged, such damage shall be repaired by the Contractor at his/her own cost and expense. If any apparatus has been subject to possible injury by water, it shall be thoroughly dried out and put through such tests as directed by the Engineer. This shall be at the cost and expense of the Contractor, or the apparatus shall be replaced by the Contractor at his/her own expense.
1.07 MEETINGS
A. The ISS shall include in his bid time and expenses for meetings at the Owner’s site or Engineer’s office, for the purpose of coordination of his work with the operations of the system. These meetings shall include but not be limited to matters concerning:
1. Report generation detailing
2. Submittal review and approval meetings
3. Graphics detailing
4. Monthly progress,
5. Project scope.
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6. For purposes of bid the ISS should include provision of one (1) day plus expenses for one (1) meeting.
1.08 PROJECT/SITE REQUIREMENTS
A. Environmental Requirements - All control cabinets (existing and new) shall be actively environmentally controlled to maintain temperatures & dewpoint within normal operating ranges of control equipment & mounted therein, if located in an un-air conditioned space.
B. Existing Conditions – The ISS shall ascertain existing range of environmental conditions at the site for appropriateness of cabinet environmental control system. This is an operating pump station and all work must be coordinated on a day to day basis with the Operation's Division.
C. Field Measurements – The ISS shall be responsible for the proper fit and adherence to applicable codes of all control equipment and cabinetry to be located in the field and electrical room. The ISS shall verify and document location of switches, transmitters, and their corresponding ranges and calibration.
1.09 MAINTENANCE
A. Tools and Test Equipment. Any specialty software or hardware tools used on this project must be turned over to the Owner.
B. Test equipment shall be provided, together with items such as an instruction manual, carrying/storage cases, unit battery charger where applicable, special tools, calibration fixtures, cord extenders, patch cords and test leads, which are not specified but are necessary for checking field operation of equipment supplied under this Section.
C. Spare Parts
1. Spare parts shall be as defined in the related specification sections. All spare parts shall be new and unused.
2. All spare parts shall be individually packaged and labeled.
3. The spares listed above shall be packed in a manner suitable for long-term storage and shall be adequately protected against corrosion, humidity and temperature.
D. Refer to Specification Sections 13310, 13315 and 13325 for additional spares and test equipment to be furnished by the ISS.
1.10 FINAL SYSTEM DOCUMENTATION
A. Prior to final acceptance of the system and Owner and/or Engineer training, operating and maintenance manuals covering instruction and maintenance on each type of equipment shall be furnished in accordance with this Section and Section 01730.
B. The instructions shall be bound in three-ring binders with Drawings reduced or folded for inclusion and shall provide at least the following as a minimum.
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1. A comprehensive index.
2. A complete "As Constructed" set of approved shop Drawings.
3. A complete list of the equipment supplied, including serial numbers, ranges, and pertinent data.
4. Full specifications on each item.
5. System schematic drawings "As Constructed", illustrating all components, piping and electrical connections of the systems supplied under this Section.
6. Detailed service, maintenance and operation instructions for each item supplied.
7. Special maintenance requirements particular to this system shall be clearly defined, along with special calibration and test procedures.
8. The operating instructions shall also incorporate a functional description of the entire system, with references to the systems schematic drawings and instructions.
9. Complete parts lists with stock numbers and name, address, and telephone number of the local ISS.
C. The ISS’s final documentation shall be new documentation written specifically for this project, but may include standard and modified standard documentation. Modifications to existing hardware or software manuals shall be made on the respective pages or inserted adjacent to the modified pages. All standard documentation furnished shall have all portions that apply clearly indicated. All portions that do not apply shall be deleted.
D. The manuals shall contain all illustrations, detailed drawings, wiring diagrams, and instructions necessary for installing, operating, and maintaining the equipment. The illustrated parts shall be numbered for identification. All information contained therein shall apply specifically to the equipment furnished and shall only include instructions that are applicable. All such illustrations shall be incorporated within the printing of the page to form a durable and permanent reference book.
E. If the ISS transmits any documentation or other technical information which he/she considers proprietary, such information shall be designated. Documentation or technical information which is designated as being proprietary will be used only for the design, construction, operation, or maintenance of the system and, to the extent permitted by law, will not be published or otherwise disclosed.
F. The requirements for the ISS’s final documentation are as follows: As built documentation shall include all previous submittals, as described in this Specification, updated to reflect the as-built system. Any errors in or modifications to the system resulting from the Factory and/or Field Acceptance Tests shall be incorporated in this documentation.
1. The Hardware Maintenance Documentation shall describe the detailed preventive and corrective procedures required to keep the system in good operating condition. Within the complete Hardware Maintenance Documentation, all hardware maintenance manuals
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shall make reference to appropriate diagnostics, where applicable, and all necessary timing diagrams shall be included. A maintenance manual or a set of manuals shall be furnished for all delivered hardware, including peripherals. The Hardware Maintenance Documentation shall include, as a minimum, the following information:
a. Operation Information - This information shall include a detailed description of how the equipment operates and a block diagram illustrating each major assembly in the equipment.
b. Preventative-Maintenance Instructions - These instructions shall include all applicable visual examinations, hardware testing and diagnostic routines, and the adjustments necessary for periodic preventive maintenance of the System.
c. Corrective-Maintenance Instructions - These instructions shall include guides for locating malfunctions down to the card-replacement level. These guides shall include adequate details for quickly and efficiently locating the cause of an equipment malfunction and shall state the probable source(s) of trouble, the symptoms, probable cause, and instructions for remedying the malfunction.
d. Parts Information - This information shall include the identification of each replaceable or field-repairable module. All parts shall be identified on a list in a drawing; the identification shall be of a level of detail sufficient for procuring any repairable or replaceable part. Cross-references between ISS’s part number and Manufacturer’s part numbers shall be provided.
PART 2 PRODUCTS
2.01 INSTRUMENTATION GENERAL
A. Type
1. All instrumentation supplied shall be of the Manufacturer’s latest design and shall produce or be activated by signals which are established standards for the water and wastewater industries.
2. All electronic instrumentation shall be of the solid-state type and shall utilize linear transmission signals of 4 to 20 mA dc (milliampere direct current), however, signals between instruments within the same panel or cabinet may be 1-5V dc (volts direct current), or the like.
3. Outputs of equipment that are not of the standard signals as outlined, shall have the output immediately raised and/or converted to compatible standard signals for remote transmission. No zero based signals will be allowed.
4. All instruments shall be provided with mounting hardware and floor stands, wall brackets, or instrument racks as shown on the Drawings or as required.
5. Equipment installed in a hazardous area shall meet Class, Group, and Division as shown on the Electrical Drawings, to comply with the National Electrical Code.
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6. All indicators and recorder readouts shall be linear in process units, unless otherwise noted.
7. All transmitters shall be provided with integral digital indicators or in process units, accurate to two percent.
8. Electronic equipment shall be of the Manufacturer’s latest design, utilizing printed circuitry and suitably coated to prevent contamination by dust, moisture and fungus. Solid state components shall be conservatively rated for their purpose, to assure optimum long term performance and dependability over ambient atmosphere fluctuations and 0 to 100 percent relative humidity. The field mounted equipment and system components shall be designed for installation in dusty, humid, and slightly corrosive service conditions.
9. All equipment, cabinets and devices furnished hereunder shall be heavy-duty type, designed for continuous industrial service. The system shall contain products of a single manufacturer, in-so-far as possible, and shall consist of equipment models which are currently in production. All equipment provided shall be of modular construction and shall be capable of field expansion.
10. The field mounted digital system equipment and system components shall be designed for installation in dusty, humid, and slightly corrosive service conditions.
11. All electronic/digital equipment shall be provided with radio frequency interference protection and shall be FCC approved.
B. Electrical
1. All equipment shall be designed to operate on a 60 Hertz alternating current power source at a nominal 120 volts, plus or minus 10 percent, except where specifically noted. All regulators and power supplied required for compliance with the above shall be provided between power supply and interconnected instrument loop. Where equipment requires voltage regulation, constant voltage transformers shall be supplied.
2. Materials and equipment used shall be U.L. approved wherever such approved equipment and materials are available.
3. All equipment shall be designed and constructed so that in the event of a power interruption, the equipment specified hereunder shall resume normal operation without manual resetting when power is restored.
2.02 LIGHTNING/SURGE PROTECTION
A. General - Lightning/Surge protection shall be provided to protect the electronic instrumentation system from induced surges propagating along the signal and power supply lines from lightning, utility, or the internal plant electrical distribution system. The protection systems shall be such that the protective level shall not interfere with normal operation, but shall be lower than the instrument surge withstand level. Protection shall be maintenance free and self restoring.
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B. Field Instrumentation Protection - Provide individual device protection for the 4-20 mA signal to each field instrument mounted outside of the building or facility housing the control panel. Instruments mounted within the structure as the associated control panel shall not require surge protection. Instruments shall be housed in a suitable metallic case, properly grounded. Ground wires for all instrumentation device surge protectors shall be connected to a good earth ground. Where practical route each ground wire individually and insulated from each other. Device surge protectors shall be mounted within the instrument enclosure or a separate junction box coupled to the enclosure. Provide surge protection devices as manufactured by Phoenix Contact, EDCO, Emerson Network Power Control Concepts, or equal.
C. Control Panel Power Feed – Provide protection of all 120 VAC power feeds into the control panels. Source voltage to cabinets/panels regardless of location (indoor or outdoor), shall be protected by isolation transformers and surge suppressors. Provide gas tube surge suppressors or metal oxide varisters (MOVs) located at the point where the 120V source supply enters the enclosure. Install the surge device to in strict compliance with the manufacturer’s recommendation for maximum allowable circuit length between protective device and incoming circuit. Provide signal surge suppression devices as manufactured by Phoenix Contact, EDCO, Emerson Network Power Control Concepts, or equal.
D. Instrument 120 V Power Supply – Provide protection for 120 VAC power to all 4-wire field instruments (indoor or outdoor). Provide individual gas tube surge suppressors or metal oxide varisters (MOVs) located at the instrument end of the circuit. Provide signal surge suppression devices as manufactured by Phoenix Contact, EDCO, Emerson Network Power Control Concepts, or equal.
E. 4-20 mA Signal Lines and Non-Fiber Based Data Highway Circuits – Provide protection on all signal and data highway circuits that leave a building or are routed external to a building. Provide gas tube surge arrestors, and Zener diode protectors. Circuit protection shall be provided at both ends of the signal or data highway lines within the control panel at one end and as close to the instruments or termination device as possible. Provide signal surge suppression devices as manufactured by Phoenix Contact EDCO, Emerson Network Power Control Concepts, or equal.
F. Inductive Loads – At a minimum, provide surge protection or interposing relays on all process controller outputs or switches rated 100 VA or less that drive solenoid, coil, or motor loads. Refer to the detailed requirements for controller output protection in the detailed technical specifications of the related section of Division 13. Provide interposing relays or signal surge suppression devices as manufactured by Phoenix Contact, EDCO, Emerson Network Power Control Concepts, or equal.
G. Telephone Circuits - At a minimum, provide telephone company approved line protection units for all telephone lines used for telemetry or SCADA system use under this Contract.
2.03 TUBING AND FITTINGS
A. All instrument air header takeoffs and branch connections less than 2-in shall be 316 stainless steel.
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B. All instrument shut-off valves and associated fittings shall be supplied in accordance with the piping specifications and all instrument installation details. Fittings shall be Swagelok 316 stainless steel or equal and valves shall be Whitney 316 stainless steel or equal.
C. All instrument tubing shall be fully annealed ASTM A269 Seamless 316 grade free of OD scratches having the following dimensional characteristics as required to fit the specific installation:
1. 1/4-in to 1/2-in O.D by 0.035 wall thickness.
2. 5/8-in to 1-in O.D by 0.049 wall thickness.
3. 1-in O.D by 0.065 wall thickness.
4. 1-1/4-in O.D by 0.065 wall thickness.
5. 1-1/2-in O.D by 0.083 wall thickness.
6. 2-in O.D by 0.95 wall thickness.
D. All process connections to instruments shall be annealed 1/2-in O.D. stainless steel tubing, Type 316.
E. All tube track shall be supported by stainless steel and installed as per manufacturer's installation instructions.
PART 3 EXECUTION
3.01 GENERAL INSTALLATION
A. Instrumentation and accessory equipment shall be installed in accordance with the Manufacturer’s instructions. The locations of equipment, transmitters, alarms and similar devices shown on the Drawings are approximate only. Exact locations shall be as approved by the Engineer during construction. Obtain in the field all information relevant to the placing of process control work and in case of any interference with other work, proceed as directed by the Engineer and furnish all labor and materials necessary to complete the work in an approved manner.
B. The instrumentation loop diagrams indicate the intent of the interconnection between the individual instruments. Any exceptions should be noted. Two complete sets of approved shop drawings shall be kept at the job site during all on-site construction. Both sets shall be identically marked up to reflect any modifications made during field installation or start-up. All markings shall be verified and initialed by the Engineer or his/her designated representative. Following completion of installation and the operational readiness test, one set of the marked up drawings shall be provided to the Engineer, the other retained by the ISS for incorporation of the mark-ups into final as-built documentation.
C. All work shall be executed in full accordance with codes and local rulings. Should any work be performed contrary to said rulings, ordinances and regulations, the Contractor shall bear full responsibility for such violations and assume all costs arising therefrom.
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D. All equipment used in areas designated as hazardous shall be designed for the Class, Group, and Division as required on the Electrical Drawings for the locations. All work shall be in strict accordance with codes and local rulings, should any work be performed contrary to said rulings, ordinances and regulations, the ISS shall bear full responsibility for such violations and assume all costs arising there from.
E. Unless specifically shown in the Drawings, direct reading or electrical transmitting instrumentation shall not be mounted on process piping. Instrumentation shall be mounted on instrument racks or stands as detailed on the installation detail drawings. All instrumentation connections shall be provided with shutoff and drain valves. For differential pressure transmitters, valve manifolds for calibration, testing, and blowdown service shall also be provided. For slurries, chemical or corrosive fluids, diaphragm seals with flushing connections shall be provided.
F. All piping to and from field instrumentation shall be provided with necessary unions, test tees, couplings, adaptors, and shut-off valves.
G. Field instruments requiring power supplies shall be provided with local electrical shutoffs and fuses as required.
H. Brackets and hangers required for mounting of equipment shall be provided. They shall be installed in a workmanlike manner and not interfere with any other equipment.
I. The ISS shall investigate each space in the building through which equipment must pass to reach its final location. If necessary, the ISS shall be required to ship his/her material in sections sized to permit passing through restricted areas in the building. The ISS shall also investigate, and make any field modifications to each cabinet, enclosure and panel to assure proper space and access (front, rear, side).
J. The shield on each process instrumentation cable shall be continuous from source to destination and be grounded as directed by the manufacturer of the instrumentation equipment but in no case shall more than one ground point be employed for each shield.
K. Lifting rings from cabinets/assemblies shall be removed. Hole plugs shall be provided for the holes of the same color as the cabinet.
L. The ISS, acting through the Contractor, shall coordinate the installation, the placing and location of system components, their connections to the process equipment panels, cabinets and devices, subject to the Engineer’s approval. The ISS shall be responsible to insure that all field wiring for power and signal circuits are correctly done in accordance with best industry practice and provide for all necessary system grounding to insure a satisfactory functioning installation. The Contractor hereunder shall schedule and coordinate the work by the ISS under this section with that of the electrical work specified under applicable Sections of Division 16.
3.02 TESTS (GENERAL)
A. As a minimum, the testing shall include the following, for the ISS:
1. Unwitnessed Factory Test (UFT)
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2. Operational Readiness Tests (ORT)
3. Functional Demonstration Tests (FDT)
4. Performance Acceptance Test (PAT)
B. Each test shall be in the cause and effect format. The person conducting the test shall initiate an input (cause) and, upon the system's or subsystem's producing the correct result (effect), the specific test requirement will have been satisfied.
C. All tests shall be conducted in accordance with prior Engineer-approved procedures, forms, and checklist. Each specific test to be performed shall be described and a space provided after it for signoff by the appropriate party after its satisfactory completion.
D. Copies of these signoff test procedures, forms, and checklists will constitute the required test documentation.
E. Provide all special testing materials and equipment. Wherever possible, perform tests using actual process variables, equipment, and data. Where it is not practical to test with real process variables, equipment, and data, provide suitable means of simulation. Define these simulations techniques in the test procedures.
F. The ISS shall coordinate all of his testing with the Engineer, all affected Subcontractors, and the Owner.
G. The Engineer reserves the right to test or retest all specified functions whether or not explicitly stated in the prior approved Test Procedures.
H. The Engineer’s decision shall be final regarding the acceptability and completeness of all testing.
I. The ISS shall furnish the services of servicemen, all special calibration and test equipment and labor to perform the field tests.
J. No equipment shall be shipped until the Engineer has received all test results and approved the system is ready for shipment.
K. Correction of Deficiencies
1. All deficiencies in workmanship and/or items not meeting specified testing requirements shall be corrected to meet specifications requirements at no additional cost to the Owner.
2. Testing, as specified herein, shall be repeated after correction of deficiencies is made until the specified requirements are met. This work shall be performed at no additional cost to the Owner.
3.03 UNWITNESSED FACTORY TESTS (UFT)
A. The entire system except for primary elements, final control elements, and field mounted transmitters shall be interconnected and tested to ensure the system will operate as specified. All control loops and programs shall be tested. All analog and discrete input/output points not
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interconnected at this time shall be simulated to ensure proper operation of all alarms, monitoring devices/functions, and control devices/functions. The intent is for the ISS to verify functionality of all components (e.g,. 100 percent I/O check to the interface terminal blocks).
B. All panels and assemblies shall be inspected and tested to verify that they are in conformance with related submittals, specifications, and Contract Drawings.
C. During the tests all digital system hardware and software shall be operated for at least five days continuously without a failure to verify the system is capable of continuous operation.
D. All temporary cables, fiber optic and copper, necessary for connecting all control system components, including the TCU control system communication cables, shall be provided by the ISS for use during the factory testing.
3.04 OPERATIONAL READINESS TESTS (ORT)
A. General: Prior to startup and the Functional Demonstration Test, the entire system shall be certified (inspected, tested, and documented) that it is READY for operation.
B. Loop/Component Inspections and Tests: The entire system shall be checked for proper installation, calibrated, and adjusted on a loop-by-loop and component-by-component basis to ensure that it is in conformance with related submittals and these Specifications.
1. The Loop/Component Inspections and Tests shall be implemented using Engineer-approved forms and checklists.
a. Each loop shall have a Loop Status Report to organize and track its inspection, adjustment, and calibration. These reports shall include the following information and checkoff items with spaces for signoff by the ISS:
1) Project Name
2) Loop Number
3) Tag Number for each component
4) Checkoffs/signoffs for each component
a) Tag/identification
b) Installation
c) Termination – wiring
d) Termination – tubing
e) Calibration/adjustment
5) Checkoffs/signoffs for the loop
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a) Panel interface terminations
b) I/O interface terminations
c) I/O signal operation
d) Inputs/outputs operational: received/sent, processed, adjusted
e) Total loop operation
6) Space for comments
b. Each active Analog Subsystem element and each I/O module shall have a Component Calibration Sheet. These sheets shall have the following information, spaces for data entry, and a space for signoff by the ISS:
1) Project Name
2) Loop Number
3) Component Tag Number of I/O Module Number
4) Component Code Number Analog System
5) Manufacturer (for Analog system element)
6) Model Number/Serial Number (for Analog system)
7) Summary of Functional Requirements. For example:
a) For Indicators and Recorders: Scale and chart ranges
b) For Transmitters/Converters: Scale and chart ranges
c) For Computing Elements: Function
d) For Controllers: Action (direct/reverse) control modes (PID)
e) For Switching Elements: Unit range, differential FIXED/ADJUSTABLE), reset (AUTO/MANUAL)
f) For I/O Modules: Input or output
8) Calibrations; for example:
a) For Analog Devices: Required and actual inputs and outputs at 0, 10, 50, and 100 percent of span, rising and falling.
b) For Discrete Devices: Required and actual trip points and reset points.
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c) For Controllers: Mode settings (PID).
d) For I/O Modules: Required and actual inputs or outputs for 0, 10, 50, and 100 percent of span, rising and falling.
9) Space for comments
10) Space for signoff by the ISS
2. The ISS shall maintain the Loop Status Reports and Components Calibration sheets at the jobsite and make them available to the Owner and/or Engineer at any time.
3. These inspections and tests do not require witnessing. However, the Engineer will review and initial all Loop Status Sheets and Component Calibration Sheets and spot-check their entries periodically and upon completion of the Operational Readiness Tests. Any deficiencies found shall be corrected.
3.05 FUNCTIONAL DEMONSTRATION TEST (FDT)
A. Prior to startup and the Functional Demonstration Test, the entire installed instrument and control system shall be certified that it is ready for operation. All preliminary testing, inspection, and calibration shall be complete as defined in the operational readiness tests.
B. Once the facility has been started up and is operating, a witnessed Functional Acceptance Test shall be performed on the complete system to demonstrate that it is operating and in compliance with these Specifications. Each specified function shall be demonstrated on a paragraph-by-paragraph, loop-by-loop basis.
C. Loop-specific and non-loop-specific tests shall be tested and all functions demonstrated on the entire installed system.
D. Updated versions of the documentation specified shall be provided and made available to the Engineer at the job-site both before and during the tests. In addition, one copy of all O&M Manuals shall be made available to the Engineer at the jobsite both before and during testing.
E. Provide a daily schedule to be followed during the Functional Acceptance Testing.
F. The system shall operate for a continuous 100 hours without failure before this test will be considered successful.
3.06 PERFORMANCE ACCEPTANCE TEST (PAT)
A. After completion of the Operational Readiness and Functional Demonstration Tests, the ISS shall be responsible for operation of the entire system for a period of 30 consecutive days, under conditions of full plant process operation, without a single non-field repairable malfunction.
B. During this test, plant operating, the ISS personnel shall be present as required. The ISS are expected to provide personnel for this test who have an intimate knowledge of the hardware and software of the system.
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C. While this test is proceeding, the Owner shall have full use of the system. Only plant operating personnel shall be allowed to operate equipment associated with live plant processes.
D. Any malfunction during the tests shall be analyzed and corrections made by the ISS. The Owner and/or Engineer will determine whether any such malfunctions are sufficiently serious to warrant a repeat of this test.
E. Any malfunction, during this 30 consecutive day test period, which cannot be corrected within 24 hours of occurrence by the ISS’s personnel, or more than two similar failures of any duration, will be considered as a non-field-repairable malfunction.
F. Upon completion of repairs, by the ISS, the test shall be repeated as specified herein.
G. In the event of rejection of any part or function, the Contractor shall perform repairs or replacement within 90 days.
H. All data base errors must be corrected prior to the start of each test period. The 30 day test will not be considered successful until all data base is correct.
I. The total availability of the system shall be greater than 99.9 percent during this test period. Availability shall be defined as "Avail. = (Total Time-Down Time)/Total Time". Down times due to power outages or other factors outside the normal protection devices or backup power supplies provided, shall not contribute to the availability test times above.
J. Upon successful completion of the 30-day PAT test and subsequent review and approval of complete system final documentation, the system shall be considered substantially complete and the one year warranty period shall commence.
3.07 TRAINING
A. General
1. The cost of training programs to be conducted with Owner’s and/or Engineer’s personnel shall be included in the Contract price. The training and instruction, insofar as practicable, shall be directly related to the system being supplied.
2. The ISS shall provide detailed manuals to supplement the training courses. The manuals shall include specific details of equipment supplied and operations specific to the project.
3. The ISS shall make use of teaching aids, manuals, slide/video presentations, etc. After the training services, such materials shall be delivered to Owner and/or Engineer
4. The training program shall represent a comprehensive program covering all aspects of the operation and maintenance of the system.
5. All training schedules shall be coordinated with, and at the convenience of the Owner. Shift training may be required to correspond to the Owner’s working schedule.
6. The Owner reserves the right to video tape all training sessions. All such tapes shall become the sole property of the Owner.
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7. The system training program shall be structured such that the operating personnel will understand the system’s operation, and the functions available in the system.
8. The level and amount of training will be based on the understanding of the individual staff members. Preventive and corrective maintenance of system devices and hardware shall be presented.
9. A number of basic theory courses shall be provided to give the operators an appreciation of how the system can help them perform their jobs.
B. Field Training
1. Field Instruments
a. Provide a minimum of one 8-hour hardware training and instructions on the maintenance of the field instrumentation for the Owner’s instrumentation technician(s). This training shall be conducted before the Functional Demonstration Test, but no more than one (1) month before and at a time suitable to the Owner. This training shall take place at the Owner’s facility. As a minimum the following shall be included:
1) Training in standard hardware maintenance for the instruments provided.
2) Specific training for the actual instrumentation configuration to provide a detailed understanding of how the equipment and components are arranged, connected, and set up for this Contract.
3) Test, adjustment, and calibration procedures
4) Troubleshooting and diagnosis
2. Panel Instruments
a. Provide a minimum of one 8-hour hardware training and instructions on the maintenance of the field instrumentation for the Owner’s instrumentation technician(s). This training shall be conducted before the Functional Demonstration Test, but no more than one (1) month before and at a time suitable to the Owner. This training shall take place at the Owner’s facility. As a minimum the following shall be included:
1) Review of the information displayed on the LCD display
2) Automatic operation of the equipment including interlocking.
3) Where provided, manual operation of the equipment.
4) Equipment alarms and appropriate operator actions.
5) Hardwired interlocks for the equipment.
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6) Modifications of set points through the TCU, for the system provided under this contract.
7) Tuning of PID loops.
8) Training in standard hardware maintenance for the panel instruments provided.
3.08 WARRANTY
A. Provide equipment warranties per section 01740, Warranties and Bonds and herein, and for special extended warranty requirements.
3.09 CONTROL SYSTEM DIAGRAMS AND DETAILS
A. To assist the ISS in determining the scope of work, a series of process and instrumentation diagrams (P&IDs) and details are provided. Unless specifically stated otherwise, the ISS shall be responsible for providing all instrumentation, control equipment and auxiliary devices necessary to perform the functions specified herein and as shown and described on these diagrams. Any auxiliary devices such as lightning/surge protectors, relays, timers, signal isolators, signal boosters, etc. which are necessary for complete operation of the system, or to perform the functions specified shall be included, whether or not they are specifically shown or tabulated on the loop diagrams.
B. The intent of the P&IDs is to depict in as much detail as possible, the hardware, software and functional requirements of a process measurement or control system. They are not intended to convey requirements for conduit and wiring between panels or system components. This information is included in appropriate electrical specifications and Drawings.
END OF SECTION
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SECTION 13305
APPLICATION ENGINEERING SERVICES
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Instrumentation System Supplier (ISS) defined in Section 13300 shall furnish all services defined herein.
B. The ISS shall provide all programming, labor, ancillary equipment and services required to achieve a fully integrated and operational system. The ISS shall configure the control system for proper operation with related equipment and materials furnished by suppliers called out under other sections of these Specifications and with related equipment.
C. Auxiliary and accessory programming structures necessary for system operation or performance shall be included whether they are shown on the Drawings or not.
D. All equipment shall be controlled in full conformity with detailed Drawings, specifications, engineering data, instructions and recommendations of the equipment manufacturer.
E. All equipment and installations shall satisfy applicable Federal, State, and local codes.
F. Supplementing this Section, the Drawings and the related Specification sections provide additional details showing panel elevations, instrument device schedules, functional requirements of the system, and interaction with other equipment.
1.02 SUBMITTALS
A. Refer to Section 13300.
1.03 REFERENCE STANDARDS
A. Refer to Section 13300.
1.04 QUALITY ASSURANCE
A. Refer to Section 13300.
1.05 SYSTEM DESCRIPTION
A. The ISS is responsible for providing all programming and configuration services and ancillary equipment to accomplish the control and monitoring functions as described in the contract specifications and drawings. The ISS shall provide all programming functions including but not limited to control strategies and communications. Configuration shall include interfacing field devices and equipment with the PLC and RTU and the existing SCADA System as depicted on the drawings and specified herein.
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B. The ISS shall develop and provide all graphic screens for the central SCADA location. The graphics shall be designed to match as closely as possible the existing SCADA application. The exact number and type of customized process graphic screens shall be determined at the coordination meeting (specified in Section 13300). The graphic displays to be developed shall represent all existing and new process flow paths and all associated equipment units, pumps, meters, valves, and auxiliary systems. The ISS shall follow the established process control operating philosophy, standard graphical layout and graphical symbolic representation for all supplied process graphics. The following is a guide for the ISS as to which graphic displays need to be developed.
C. Graphical Displays. The following shall be incorporated into the existing SCADA system, as a minimum, as the following and as shown on P&IDs.
1. Graphical Process Displays
a. Pump Station Overview
b. Pump Station Wet Well Level
c. Pump Station Flow and Pressure
d. Miscellaneous Monitoring (Generator, Fuel Storage Tank, etc.) as shown on drawings
2. Group Bargraph/Controller Faceplate Displays
a. Pump Station flow and pressure
b. Pumps speed control
c. Wet Well level
3. Trend Displays
a. Trend overview
b. Pump Station flow and pressure
c. Wet Well level
PART 2 PRODUCTS
2.01 (None this Section.)
PART 3 EXECUTION
3.01 GENERAL
A. Refer to Section 13300.
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3.02 TESTS
A. Refer to Section 13300.
END OF SECTION
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SECTION 13315
FIELD INSTRUMENTATION
PART 1 GENERAL
1.01 SCOPE OF WORK
A. This Specifications Section covers the furnishing, installation, and services for the field mounted instruments major systems, panels, and subassemblies as detailed on the Drawings and in the Loop Diagrams.
B. Refer to Specifications Section 13300.
1.02 RELATED WORK
A. Refer to Specifications Section 13300.
1.03 SUBMITTALS
A. Refer to Specifications Section 13300.
1.04 REFERENCE STANDARDS
A. Refer to Specifications Section 13300.
1.05 QUALITY ASSURANCE
A. Refer to Specifications Section 13300.
1.06 MAINTENANCE AND TEST EQUIPMENT
A. In addition to the tools and test Equipment specified in Specifications Section 13300, provide the following complete with carrying cases, patch cords, etc.
1. One portable calibrator and accessories for the combustible gas monitors, provided by the same Manufacturer.
B. Spare Parts:
1. Miscellaneous Spare Parts:
a. One year supply of desiccants for each submersible depth level pressure transducer supplied.
b. One year supply of items recommended by the Manufacturer of the Equipment for each component furnished under this Contract.
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c. Provide spares of one of each type of instrument furnished under this Specification Section excluding the magnetic flow meter.
2. The spares listed above shall be packed in a manner suitable for long-term storage and shall be adequately protected against corrosion, humidity and temperature.
3. Provide other spare parts as indicated on the individual device Specifications.
PART 2 PRODUCTS
2.01 COMBUSTIBLE GAS DETECTOR
A. Sensor:
1. Type:
a. Intrinsically safe
b. Infrared Technology Gas Detector
2. Function/Performance:
a. To sense the presence of combustible gases and vapors, primarily Methane, prior to reaching lower explosive limit (LEL).
b. Operating Temperature: -65 to +200 degrees F, and Humidity 95%.
c. Sensor Life: Three (3) years.
d. Measuring Range: 0 – 100% LEL.
e. Alarm Settings: Field adjustable.
3. Physical:
a. Housing: Class 1, Division 1, Groups B, C, & D.
B. Indicating Transmitter:
1. Type:
a. Electronic microprocessor based.
b. Lower explosive limit (LEL) indicator.
2. Functional/Performance:
a. Power requirements: 120 VAC
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b. Temperature: 0 to 150 degrees C
c. Indicates combustible gas concentration with alphanumeric 3 digit LED and is provided with front mounted LED lights for alarms.
d. Output contact for remote indication of high combustible gas alarm.
3. Physical:
a. NEMA 4X wall enclosure, rack-mounted with rain hood. Refer to Electrical Drawings for location.
4. Accessories/Options Required:
a. Cable: Provide 3-wire shielded cable between remote-mounted sensor and transmitter or Manufacturer’s cable.
b. Provide calibration gas and kit and one year supply of spare parts.
c. Provide filter, pump, tubing, and other accessories required for a sample-draw system.
C. Manufacturer(s):
1. MSA International.
2. General Monitors.
3. Or approved equal.
D. Units To Be Supplied By ISS:
1. AE/AIT-120: Intermediate Pump Station (IPS) Combustible Gas Detector
2. AE/AIT-220: Lift Station 1 (LS-01) Combustible Gas Detector
2.02 MAGNETIC FLOWMETER
A. Flow Element
1. Type: Magnetic flowmeter, operating based on Faraday’s law, using a pulsed dc type coil excitation with high impedance electrodes.
2. Function/Performance:
a. Power requirements: Match to converter/ transmitter.
b. Range: 1000 to 1 6” and smaller, 1500 to 1 8” and larger.
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c. Accuracy: 1/2” to 6” 0.2% of rate, 8” and larger 0.15% of rate with a repeatability of 0.05% or 0.0008ft/s, whichever is greater.
d. Temperature rating: Suitable for process liquid temperature up to 70 degrees C and an ambient of 60 degrees C.
e. RFI protection: Provide RFI protection.
f. Pressure rating: 240 PSI if 150 lb flanges are used, 700 PSI if 300 lb flanges are used.
g. Additional: Meter shall be capable of running empty indefinitely without damage to any component.
3. Physical:
a. Metering Tube: 304 stainless steel unless otherwise indicated.
b. Flanges: ANSI 150 lb, carbon steel unless otherwise indicated.
c. Liner: Polyurethane unless noted otherwise.
d. Electrodes: 316 stainless steel elliptical self cleaning type unless otherwise noted.
e. Housing: Flow meter shall be designed for continuous submergence in 30 ft of water. Where hazardous areas are indicated on the contract drawings, the equipment shall be rated for that area.
f. Painting: All external surfaces shall be painted with a chemical and corrosion resistant epoxy finish.
4. Accessories/Options Required:
a. Factory calibration: All meters shall be factory calibrated. A copy of the report shall be in the O&M manual.
b. Test Mode: Provide the ability to verify the accuracy of the unit and the integrity of the current loop without any external equipment.
c. Grounding: Meter shall be grounded per the manufacturer’s recommendation. Provide ground ring, ground wires, and gaskets, etc., as required or as otherwise noted. All materials shall be suitable for liquid being measured.
d. Test equipment: see Maintenance and Test Equipment.
e. Meters to be designed, manufactured, and calibrated in an ISO9001, NAMAS, NIST, NATA certified facility
B. Flow Converter/Transmitter
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1. Type: Match to flow element.
2. Functional/Performance:
a. Power Requirements: 120VAC plus or minus 10 percent.
b. Accuracy: As defined for flow element.
c. Temperature: minus 25 degrees C to plus 65 degrees C.
d. Output: Isolated 4 20 mA into 0 to 1000 ohms.
e. Indicator: Provide local digital indicator with scale in engineering units which indicates actual flow rate.
f. Zero Return: The magmeter output shall be driven to 4 mA DC under no-flow conditions.
3. Physical:
a. Housing: NEMA 4X rack mounted on Electrical equipment rack. Refer to Electrical Drawings.
4. Accessories/Options Required:
a. Cable: Provide signal cable between magnetic flowmeter and signal converter to provide for remote mounting of the signal converter.
b. Totalizer: According to the requirements of the Loop Diagram, provide a seven digit, resettable or non-resettable totalizer on the face of the enclosure and a scalable pulse output to drive the totalizer. The totalizer multiplier shall be a power of 10.
c. Password Protection – Meter Software shall incorporate dual password features to prevent inadvertent program or unit changes.
d. Provide programmer(s) as specified under tools and test equipment.
e. Provide lightning surge protection. Refer to Specification Section 13300.
f. Provide rain hood for all outdoor installations.
C. Manufacturer(s):
1. Yokogawa, no substitutions accepted.
D. Units To Be Supplied By ISS:
1. FE/FIT-110: Intermediate Pump Station (IPS) Discharge Flow a. Meter Size: 12 Inches b. Line Size: 12 Inches
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c. Flow Range: 0-3000 GPM
2.03 RADAR LEVEL METER
A. Type: Non-contact, microwave type level meter.
B. Function/Performance
1. Measuring Range: Range as indicated in the Instrument Device Schedule, up to 50 ft (15m).
2. Accuracy: Plus or minus 0.3 percent or plus or minus 1.2 inches (30mm), whichever is greater.
3. Operating Temperature: –40 to 60 degrees C.
4. Output: Isolated 4-20 mA output.
5. Display: Digital indicator displaying level or volume in engineering units or percent, as indicated on the Drawings or in the Instrument Device Schedule.
6. Diagnostics: On-screen instructions and display of self-diagnostics.
C. Physical
1. Instrument shall be provided with a stainless steel three-inch Class 150 pound (DN 80, PN16) mounting flange.
2. Housing shall be NEMA 4X (IP66). Where the instrument is installed in a hazardous area, the housing shall be explosion-proof, approved for Class I, Division 1, Groups C and D (EEx d IIB T4) installation. The instrument shall be certified for installation of the antenna in a Class I, Division 1, Groups C and D (Zone 0) environment.
3. A/C power will be as specified in Section 13300.
D. Accessories Required
1. Where required for calibration/programming, a hand-held programmer shall be provided.
E. Manufacturer(s):
1. Ohmart/VEGA, VEGAPULS. No substitutes accepted.
F. Units to be Furnished by ISS:
1. LE/LIT-100: Intermediate Pump Station (IPS) Wetwell Level a. Range: 0-x feet
2. LE/LIT-200: Lift Station 1 (LS-01) Wetwell Level a. Range: 0-x feet
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2.04 FLOAT SWITCH
A. Type: Mercury free ball float switch.
B. Function/Performance
1. Differential: Less than 8 inches.
2. Switch Rating: 1 amps at 120 VAC or 100 VA @ 120 VAC.
3. Provide NO or NC type contact for fail-safe operation per section 13300-2.01.F or as shown on the drawings.
C. Physical
1. Float: 316 stainless steel, Teflon or non-stick coating, minimum 5 in diameter.
2. Totally encapsulated switch.
3. Cable shall be heavy-duty, PVC or equivalent jacketed integral to float.
D. Options/Accessories Required
1. Provide stainless steel hardware.
2. Lead wire shall be a waterproof cable of sufficient length so that no splice or junction box is required in the vault.
3. Provide cast aluminum weatherproof junction box outside the sump pit with terminals for all floats and tapped as required for conduit connections.
E. Manufacturer(s):
1. Contegra FS 90
2. Siemens Water Technologies Model 9G-EF
3. Anchor Scientific SST-NM
4. Or equal.
F. Units to be Furnished by ISS:
1. LSH/LSL-100: Intermediate Pump Station (IPS) Wetwell Level High/Low a. LSH Elevation: b. LSL Elevation:
2. LSH/LSL-200: Lift Station 1 (LS-01) Wetwell Level High/Low a. LSH Elevation:
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b. LSL Elevation:
2.05 LIMIT SWITCH
A. Type: Direct opening 2 position snap action, for mounting on check valve.
B. Function/Performance:
1. Minimum 2 double pole single throw (DPST) NO contacts or 2 double pole double throw (DPDT) contacts.
C. Physical:
1. Lever or button style spring return actuator.
2. Contact rating for 120 VAC/30 VDC, 100VA minimum.
D. Accessories/Options Required:
1. Non-corrosive, NEMA 4X.
2. If a sealed pre-wired switch is used, a separate connection or junction box of equal environmental protection rated will be supplied and installed.
E. Manufacturer(s):
1. Allen-Bradley.
2. Microswitch.
3. Square D.
4. Or equal.
F. Units to be Furnished by ISS:
1. ZS 101: Intermediate Pump Station (IPS) Pump No. 1 Flow Disagreement Switch
2. ZS 102: Intermediate Pump Station (IPS) Pump No. 2 Flow Disagreement Switch
3. ZS 201: Lift Station 1 (LS-01) Pump No. 1 Flow Disagreement Switch
4. ZS 202: Lift Station 1 (LS-01) Pump No. 2 Flow Disagreement Switch
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PART 3 EXECUTION
3.01 GENERAL INSTALLATION
A. Refer to Specifications Section 13300.
3.02 FIELD TESTS
A. Refer to Specifications Section 13300.
3.03 TRAINING
A. Refer to Specifications Section 13300.
END OF SECTION
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SECTION 13325
CONTROL PANELS AND PANEL MOUNTED EQUIPMENT
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Refer to Section 13300.
B. The ISS shall provide the new Pump Station control panels as specified herein and shown on the Drawings. Each panel shall be NEMA 4X, 316 stainless steel enclosure.
1.02 SUBMITTALS
A. Refer to Section 13300.
1.03 REFERENCE STANDARDS
A. Refer to Section 13300.
1.04 DELIVERY, STORAGE AND HANDLING
A. The panels shall be mounted on wood skids. Adequate crating will be provided for the panel being shipped where a transfer from one truck to another is planned.
B. Instruments shall be blocked and tied to prevent damage during shipment. Front-panel mounting instruments shall be removed and prepacked in their original containers for shipment.
C. Accessories, drawings, instructions, etc., shall be packed and shipped with the panel.
D. Refer to Section 13300.
1.05 PROJECT/SITE REQUIREMENTS
A. Refer to Section 13300.
1.06 MAINTENANCE
A. Refer to Section 13300.
B. Spare Parts: In addition to the spare parts listed in other instrumentation sections, provide the following:
1. Fuses: 20 percent of each size and type use, but no less than ten of each size and type.
2. Relays: 10 percent of each type used, but no less than five of each type.
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3. Indicating Light Bulbs: 25 of each size and type used.
4. DC Power Supplies: 20 percent of each size and type used, but no less than two of each size and type.
5. One spare analog controller of each type used (if applicable).
6. One spare analog indicator of each type used (if applicable).
7. Corrosion Inhibiting Vapor Capsules: Provide 10 of each type and size used.
C. The spares listed above shall be packed in a manner suitable for long-term storage and shall be adequately protected against corrosion, humidity and temperature.
1.07 WARRANTY
A. Refer to Section 13300.
1.08 FINAL DOCUMENTATION
A. Refer to Section 13300.
PART 2 PRODUCTS
2.01 GENERAL
A. Refer to Section 13300.
2.02 CONTROL PANEL GENERAL REQUIREMENTS
A. Furnish and install the panels per Specifications and Drawings.
B. The construction and wiring shall be in accordance with this Specification and applicable panel drawings. The panel drawings will specify the arrangement of instruments to be mounted on the front, rear, and sides of the panels.
C. Unless otherwise specified on applicable panel drawings, all panels shall be of the fully enclosed type designed for use with high-density instrumentation mounting.
D. All panel doors shall have a lock installed in the door handle, or a hasp and staple for padlocking. Locks for each local panel provided under this Contract shall be keyed alike.
E. The instruments designated for rear-of-panel mounting shall be arranged within the panel according to respective panel drawings and in a manner to allow for ease of maintenance and adjustment.
F. Conductors running from the field to the panels shall be continuous without splices, except at approved junction boxes. The junction boxes shall have terminal blocks with 20 percent spare terminals. Special care shall be exercised to carry grounding lines through such junction boxes with the least possible resistance. Cables entering panels shall be multiconductor. Conduit and
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multiconductor cables entering panels shall be sealed to prevent the intrusion of gas and moisture.
G. Multiconductor cable shall be used between junction boxes and the panels.
H. All components shall be mounted in a manner that shall permit servicing, adjustment, testing and removal without disconnecting, moving or removing any other component. Components mounted on the inside of panels shall be mounted on removable plates, in such a manner that the component may be removed without removing the plate, and not directly to the enclosure. Mounting shall be rigid and stable unless shock mounting is required otherwise by the manufacturer to protect equipment from vibration. Mounting orientation shall be in accordance with the requirements of each component. Components shall be identified with suitable plastic or metal engraved tags attached with drive pins adjacent to (not on) each component identifying the component in accordance with the Drawings, Specifications, and ISS's data.
I. The internal framework of each panel shall permit panel lifting without racking or distortion. Provide removable lifting rings designed to facilitate simple, safe rigging and lifting of the control panels during installation. Plugs shall be provided and shall unobtrusively fill the panel lifting ring holes when substituted for the lifting rings after installation is complete.
J. All exterior panel mounted equipment shall be installed with suitable gaskets, faceplates, etc. required to maintain the NEMA rating of the panel.
K. All panels shall be supplied with suitable nameplates which identify the panel and individual devices as required. Nameplates shall be provided for all flush mounted equipment in the interior and exterior of each panel. Nameplates shall be approximately 1-in x 3-in constructed of white and black laminated, phenolic material having engraved helvetica letters approximately 1/4-in high, extending through the white face into the black layer. Nameplates shall be beveled and attached to panels by self tapping stainless steel screws. Adhesive bonded or glued on name plates shall not be accepted.
2.03 PANEL MATERIALS AND CONSTRUCTION
A. General
1. All panels located in outdoor areas, or in indoor areas where specified in the Contract Documents, shall be of NEMA 4X construction and shall be labeled by Underwriters Laboratories.
a. Freestanding panels, and all those specified as stainless steel in the Drawings, shall be constructed of 316 Stainless Steel. Minimum thickness shall be 12 gauge for freestanding panels, 14 gauge for wall or Unistrut mounted panels. Continuous door hinge, hinge pin, three point latches, hasp and staple for padlocking, shall be of stainless steel construction. Interior panels of 10 gauge steel construction shall be provided where necessary for instrument mounting.
2. Provide explosion-proof enclosures where required in hazardous areas.
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3. Panels shall be provided with full length, fully gasketed rear doors or front access doors as shown on the panel details. Front access doors with mounted instruments or control devices shall be of sufficient width to permit door opening without interference from flush mounted instruments. For freestanding panels, full length rear access door shall be not greater than 24-in in width.
4. The panel shall be suitable for top or bottom conduit entry as required by the Electrical Drawings. For top mounted conduit entry the panel top shall be provided with nominal one foot square removable access plates which may be drilled to accommodate conduit and cable penetrations. All conduit and cable penetrations shall be provided with ground bushings, hubs, gasketed locknuts, or other accessories as required to maintain the NEMA rating of the panel and electrical rating of the conduit system.
B. Finish Requirements
1. All sections shall be descaled, degreased, filled, ground and finished. The enclosure, when fabricated of carbon steel, shall be finished with two rust resistant phosphate prime coats and two coats of enamel, polyurethane, or lacquer finish which shall be applied by either the hot air spray or conventional cold spray methods. Stainless steel panels will not require a paint finish.
2. The panels shall have edges ground smooth and shall be sandblasted and then cleaned with a solvent. Surface voids shall be filled and ground smooth.
3. Immediately after cleaning, one coat of a rust-inhibiting primer shall be applied inside and outside, followed by an exterior intermediate and top coat of a two-component type epoxy enamel. A final sanding shall be applied to the intermediate exterior coat before top coating.
4. Apply a minimum of two coats of flat white lacquer on the panel interior after priming.
5. Unless otherwise noted, the finish exterior colors to be used shall be selected by the Owner from color clips supplied by the System Supplier.
C. Manufacturer
1. All panels shall be by Hoffman, or equal.
2.04 TEMPERATURE CONTROL
A. Forced air ventilation fans, where used, shall provide a positive internal pressure within the panel and shall be provided with washable or replaceable filters. Fan motors shall operate on 120-volt, 60-Hz power.
B. NEMA 4X rated panels that are exposed to sunlight shall be equipped with adequate sunshields. The sunshield shall consist of one or more pieces of stainless steel, FRP, or other suitable material of sufficient size to cover the top, sides, and rear of the panel, and to hang over the front of the panel to shade any instruments mounted there. If the overhang of the top sunshield does not provide adequate shade the panel-mounted instruments, an additional sunshield shall be furnished on the panel for that instrument. Sunshield pieces shall be
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secured to the panel by bolts and shall have no less than 1 inch of clearance from the panel and from one another, to allow for air circulation over the sunshield surfaces and access to panel door(s).
C. If necessary to maintain temperature, control panel shall be provided with a side-mounted air conditioner, manufactured by Hoffman or equal. The internal temperature of the panel shall be regulated so as not to exceed 100 degrees Fahrenheit. Under no circumstances shall the panel cooling equipment compromise the NEMA rating of the panel.
2.05 CORROSION CONTROL
A. Panels shall be protected from internal corrosion by the use of corrosion-inhibiting vapor capsules as manufactured by Northern Instruments Model Zerust VC; Hoffman Engineering Model A-HCI; or equal.
2.06 INTERNAL CONSTRUCTION
A. Internal Electrical Wiring
1. Panel equipment shall be mounted and wired on or within the cabinet. Wiring shall comply with the National Electrical Code. Wiring within the panel shall be grouped together with harnesses or ducts and secured to the structure. Wiring shall be numbered in compliance with the numbering system used on the wiring/connection diagrams. Wiring and connection diagrams shall comply with ISA S5.4 Instrument Loop Diagrams and shall be submitted by the manufacturer as part of the Shop Drawings for review by the Engineer.
2. Power and low voltage DC signal wiring shall be routed in separate wire ways. Crossing of the two system wires shall be at right angles.
3. Power wire shall be 14 AWG Type THWN stranded and shall be insulated for not less than 600 volts unless specified otherwise. Conductors shall be of tinned copper construction. All interconnecting wiring, except for electronic circuits, shall be rated for not less than 90 degrees C.
4. Signal wire shall be 1 pair 16 AWG shielded. Conductors shall be of tinned copper construction.
5. Wire color shall be: Line Power - Black; Neutral or Common - White; AC Control - Red; DC Control - Blue; Equipment or Chassis Ground - Green; specified externally powered circuits - Orange. Graphic light wiring (24 volt maximum at the lamp socket) may be 22 AWG if properly fuse protected and terminated in a terminal block capable of accepting No. 14 AWG field wiring.
6. Wiring shall terminate at a master terminal board, rigid type and numbered. The master terminal board shall have a minimum of 20 percent spares.
7. Terminal blocks shall be arranged in vertical rows and separated into groups (Power, AC control, DC signal, and alarm).
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8. Terminal strips shall be provided for the purpose of connecting all control and signal wiring. Terminal blocks shall be Phoenix style, IEC rated, Allen Bradley model AB1492- H1 or equal, with the appropriate voltage rating (600 volts minimum).
9. Wiring trough for supporting internal wiring shall be plastic type with snap on covers. The side walls shall be open top type to permit wire changing without disconnecting. Trough shall be supported to the subpanel by using stainless steel screws. Trough shall not be bonded to the panel with glue or adhesives.
10. Wire connectors shall be the hook fork type with insulated barrel for crimp type compression connection to the wire.
11. Each wire shall be provided with a numbered heat shrink tubing identification markers at both ends and the numbering shall be in accordance with the Control Panel Drawings. Identification markers shall be pretyped. Handwritten markers or paper markers will not be permitted. Each individual wire shall be assigned a single number, which shall include the Loop Number shown in the Drawings, which shall be marked on both ends of the wire.
12. Direct interlock wiring between equipment will not be allowed. Only one side of a terminal block row shall be used for internal wiring. The field wiring side of the terminal shall not be within 6-in of the side panel or adjacent terminal.
13. Wiring troughs shall not be filled to more than 60 percent visible fill. Wiring trough covers shall be match marked to identify placement. If component identification is shown on covers for visibility, the ID shall also appear on the mounting sub-panel.
14. Each panel shall have a single tube, fluorescent light fixture, 20 Watt in size, mounted internally to the ceiling of the panel. Light fixture shall be switched and shall be complete with the lamp.
15. Each panel shall have a specification grade duplex convenience receptacle mounted internally within a stamped steel device box with appropriate cover.
16. Each panel shall be provided with an isolated copper grounding bus for all signal and shield ground connections. Shield grounding shall be in accordance with the instrumentation manufacturer's recommendations.
17. Each panel shall be provided with a separate copper power grounding bus (safety) in accordance with the requirements of the National Electrical Code.
18. Each panel, where applicable, shall be provided with analog signal isolation (I/I) where analog signals are sent from one panel or console to another.
19. Each panel shall be provided with surge suppression protection (electrical transients) for connections between AC power systems and electrical and electronic equipment. Surge suppressor grounding shall be accordance with the manufacturer's recommendations. Refer to Specifications Section 13300, Paragraph 2.02 for lightening/surge protection specifications.
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20. Each panel shall be provided with a fused power disconnect switch.
21. All wiring to hand switches and the like which are live circuits independent of the panel's normal circuit breaker protection shall be clearly identified as such.
22. Each digital output shall be wired to an interposing relay and one normally open contact from each relay shall be wired out to the terminal strips.
B. Pneumatic Tubing
1. Refer to Section 13300.
C. Print Storage Pockets
1. Print storage pockets shall be provided on the inside of each panel. Its size shall be sufficient to hold all of the prints required to service the equipment.
2.07 PANEL MOUNTED INSTRUMENTS (IF REQUIRED)
A. Panel Meter (Digital Readout)
1. Type
a. Digital process meter, numerical type.
2. Functional/Performance
a. Accuracy - 99.9 percent.
b. Power requirements - 120 VAC or 24 VDC as required.
c. Operating temperature - 0 to 60 degrees C
d. Display - LED display, 3-1/2 digit minimum resolution. The indicator shall indicate the value of the analog input signal in engineering units with scale range as noted. Decimal point shall be field selectable. Unit shall provide overrange indication.
3. Physical
a. Housing - High impact plastic with splashproof lens cover and gasketing to meet NEMA 12 requirements.
b. Legend - Provide a permanent service legend to display the engineering units of the process variable.
4. Manufacturers
a. Action Instruments
b. Newport Electronics
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c. General Electric
2.08 MISCELLANEOUS PANEL COMPONENTS (IF REQUIRED)
A. Pilot Type Indicating Lights
1. Type
a. Heavy duty oiltight type which utilizes a low voltage lamp, push-to-test.
2. Functional/Performance
a. Units shall be provided with low voltage lamps suitable for the voltage supplied. Lights supplied with 120 VAC power shall have integral reduced voltage transformers.
b. Lamps shall be replaceable from the front of the unit.
3. Physical
a. Lens color shall be as indicated on the instrument device schedule. Lens shall be approximately 1-1/4-in in diameter.
b. Provide legend faceplates engraved to indicate the required function of each device.
c. Units shall be rated NEMA 13 for indoor panels. Units located outdoors or indicated to be weatherproof shall be rated NEMA 4X.
4. Manufacturers
a. Microswitch
b. Allen Bradley
c. General Electric
B. Rotary Hand Switches and Pushbuttons
1. Type
a. Control devices shall be heavy duty oiltight type with stackable contact blocks.
2. Functional/Performance
a. Provide contact arrangement and switching action as required for the control system specified.
3. Physical
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a. For 120 VAC service provide contacts rated 10 Amps at 120 VAC, for 24 VDC service provide silver sliding contacts rated 5 Amps at 125 VDC, for electronic (millivolt/ milliamp) switching provide contacts rated lamp at 28 VDC.
b. Pushbuttons shall have flush type operators. Selector switches shall have knob or wing lever operators.
c. Units shall be rated NEMA 13 for indoor service. Units located outdoors or indicated to be weatherproof shall be rated NEMA 4X.
d. Provide legend plates denoting switch/pushbutton position/ function.
4. Options/Accessories Required
a. Provide lock-out-pushbuttons, key-operators, etc, as indicated on the instrument device schedule.
b. Provide make-before-break bridging contacts where required.
5. Manufacturers
a. Microswitch
b. Allen Bradley
c. General Electric
C. Potentiometers
1. Type
a. Potentiometers shall be of the heavy duty type.
2. Functional/Performance
a. Potentiometers shall be of the three wire type with a total resistance of 1000 ohms. Units shall be rated 2 watts. Linearity shall be plus or minus 5 percent.
3. Physical
a. Units shall be rated NEMA 13 or NEMA 4 for indoor panels. Units used on outdoor panels or indicated as weatherproof shall be rated NEMA 4X.
b. Provide a legend plate with resolution of 1 percent of entire span of potentiometer.
4. Manufacturers
a. Allen Bradley
b. Micro Switch
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c. General Electric
D. Industrial Relays and Time Delays
1. Type
a. Industrial heavy duty relays.
2. Functional/Performance
a. Contact arrangement/function shall be as required to meet the specified control function specified.
b. Contacts shall be rated 10 Amps continuous at 600 Volts.
c. Relays shall be provided with convertable contact blocks.
d. Pneumatic time delay relays shall be used on time delays less than 180 seconds and shall be adjustable.
e. Solid state time delay relays shall be used on time delays between 180 seconds and one-hour.
3. Options/Accessories Required
a. Provide all mounting rails, etc, that are required.
4. Manufacturers
a. Square D
b. Allen Bradley
c. Agastat
E. General Purpose Relays and Time Delays
1. Type
a. Units shall be of the general purpose plug-in type.
2. Functional/Performance
a. Coil voltage shall match supply voltage.
b. Contact arrangement/function shall be as required to meet the specified control function.
c. Mechanical life expectancy shall be in excess of 10 million.
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d. Duty cycle shall be rated for continuous operation.
e. Units shall be provided with integral indicating light to indicate if relay is energized.
f. Solid state time delays shall be provided with polarity protection (DC units) and transient protection.
g. Time delay units shall be adjustable and available in ranges from .1 second to 4.5 hours.
3. Physical
a. For 120 VAC service provide contacts rated 10 Amps at 120 VAC, for 24 VDC service provide contacts rated 5 Amps at 28 VDC, for electronic (milliamp/millivolt) switching applicator provide gold plated contacts rated for electronic service.
b. Relays shall be provided with dust and moisture resistant covers.
4. Options/Accessories Required
a. Provide mounting sockets with pressure type terminal blocks rated 300 Volt and 10 Amps.
b. Provide mounting rails/holders as required.
5. Manufacturers
a. Danaher/Eagle Signal
b. Allen Bradley
c. Potter & Brumfield
F. Signal Relay Switches (Current Trips)
1. Type
a. Solid state electronic type.
2. Functional/Performance
a. Input - 4-20 mA
b. Output - Isolated contact output, double pole double throw, rated 5 Amps at 120 VAC.
c. Accuracy - 0.1 percent.
d. Protection - Provide RFI protection.
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e. Deadband - Adjustable between 0.1 and 5.0 percent of span.
f. Setpoint Adjustment - Provide graduated dial for each alarm set point from 0 to full scale. Alarms shall be adjustable to trip on rising or falling input signal.
g. Repeatability - Trip point repeatability shall be at least 0.1 percent of span.
3. Physical
a. Mounting - Suitable for mounting in an enclosure or high density instrument rack.
4. Options/Accessories Required
a. Mounting rack or general purpose enclosure as required.
5. Manufacturers
a. Rochester Instrument Systems
b. Acromag Inc.
c. Moore Industries
G. Signal Isolators/Boosters/Converters
1. Type
a. Solid state electronic type.
2. Functional/Performance
a. Accuracy - 0.15 percent.
b. Inputs - Current, voltage, frequency, temperature, or resistance as required.
c. Outputs - Current or voltage as required.
d. Isolation - There shall be complete isolation between input Circuitry, output circuitry, and the power supply.
e. Adjustments - Zero and span adjustment shall be provided.
f. Protection - Provide RFI protection.
3. Physical
a. Mounting - Suitable for mounting in an enclosure or instrument rack.
4. Options/Accessories Required
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a. Mounting rack or general purpose enclosure as required.
5. Manufacturers
a. Rochester Instrument Systems
b. Acromag Inc.
c. Moore Industries
H. Signal Selectors, Computation, and Conditioning Relays
1. Type
a. Solid state electronic type.
2. Functional/Performance
a. Inputs - 4-20 mA
b. Outputs - 4-20 mA
c. Protection - Provide RFI protection.
d. Operation - The relay shall multiply, add, subtract, select, extract the square root, or perform the specified conditioning/computation function required. All inputs shall be able to be individually rescaled and biased as required.
e. Isolation - All inputs, outputs, and power supplies shall be completely isolated.
f. Accuracy - 0.35 percent of span.
g. Adjustments - Multiturn potentiometer for zero, span, scaling, and biasing.
3. Physical
a. Mounting - Suitable for mounting in an enclosure or instrument rack.
4. Options/Accessories Required
a. Mounting rack or general purpose enclosure as required.
5. Manufacturers
a. Rochester Instrument Systems
b. Acromag Inc.
c. Moore Industries
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I. Intrinsically Safe Relays
1. Type
a. Relays shall be of the solid state electronic type in which the energy level of the sensing or actuation circuit is low enough to allow safe usage in hazardous areas.
2. Options/Accessories Required
a. Relays shall match power supply provided.
b. Relays shall be located in non-hazardous areas.
3. Manufacturers
a. Consolidated Electric
b. Gems Safe-Pak
c. Warrick Controls
d. R. Stahl, Inc.
PART 3 EXECUTION
3.01 INSTALLATION
A. The panels shall be installed at locations as shown on the Drawings.
B. Panels shall be factory tested prior to shipment. Field installation shall consist only of setting the panel in place and making necessary electrical and conduit connections.
C. Refer to Section 13300.
3.02 TESTS (GENERAL)
A. Panels and panel assemblies shall be tested for proper operation at the Instrumentation System Supplier's factory, or other selected site, prior to the shipment of any panel to the Jobsite.
B. Prior to shipment, an Unwitnessed Factory Test shall be performed at the System Supplier's factory, or other selected site, on panels provided. The test shall demonstrate specified functions by simulating inputs and outputs to the panels.
C. Acceptance of shop tests by Owner or Engineer shall not constitute a waiver of requirements to meet the field tests under specified operating conditions, nor does inspection relieve the manufacturer of his responsibility in any way.
D. Refer to Section 13300.
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3.03 FIELD TESTS
A. Refer to Section 13300.
3.04 TRAINING
A. Refer to Section 13300.
END OF SECTION
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SECTION 15110
WASTEWATER VALVES AND APURTENANCES
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required and install complete and ready for operation all valves and appurtenances as shown on the Drawings and as specified herein.
B. The equipment shall include, but not be limited to, the following:
1. Eccentric Plug Valves 2. Check Valves 3. Pinch Check Valves 4. Vacuum Breakers 5. Air Release Valves 6. Corporation Stops 7. Flange Adapter Couplings 8. Flexible Couplings 9. Diaphragm Seals 10. Unions 11. Mechanical Type Seals 12. Hose End Faucets 13. Pressure Gauges 14. Reduced Pressure Backflow Preventor 15. Flow Meters
1.2 DESCRIPTION OF SYSTEMS
A. All of the equipment and materials specified herein are intended to be standard for use in controlling the flow of wastewater and reclaimed water.
1.3 QUALIFICATIONS
A. All of the types of valves and appurtenances shall be products of well established reputable firms who are fully experienced, reputable and qualified in the manufacture of the particular equipment to be furnished. The equipment shall be designed, constructed and installed in accordance with the best practices and methods and shall comply with these specifications as applicable.
1.4 SUBMITTALS
A. Submit within 30 days after execution of the contract a list of materials to be furnished, the names of the suppliers and the date of delivery of materials to the site.
B. Complete shop drawings of all valves and appurtenances shall be submitted to the ENGINEER for approval in accordance with the requirements of Section 01340 and the General Conditions. 5000-79695 15110-1 Florida Governmental Utilities Authority Waterway Estates Interconnect 60% Submittal
1.5 TOOLS
A. Special tools, if required for normal operation and maintenance shall be supplied with the equipment.
PART 2 PRODUCTS
A. General:
1. All valves and appurtenances shall be of the size shown on the Drawings and as far as possible all equipment of the same type shall be from one manufacturer.
2. All valves and appurtenances shall have the name of the maker and the working pressure for which they are designed cast in raised letters upon some appropriate part of the body.
B. Eccentric Plug Valves
1. All valves shall be eccentric plug valves unless otherwise specified. Valves shall be as manufactured by DeZurik, Homestead, or approved equal.
2. Plug valves shall be tested in accordance with AWWA C504 Section 5. Each valve shall be performance tested in accordance with AWWA C504 Section 5.2 and shall be given a leakage test and hydrostatic test as described in AWWA C504 Paragraphs 5.3 and 5.4. The leakage test shall be applied to the face of the plug tending to unseat the valve. The Manufacturer shall furnish certified copies of reports covering proof of design testing as described in AWWA C504 Section 5.5.
3. Plug valves shall be of the tight closing, resilient faced, non-lubricating variety and shall be of eccentric design such that the valve's pressure member (plug) rises off the body seat contact area immediately upon shaft rotation during the opening movement. Valve pressure ratings shall be as follows and shall be established by hydrostatic tests as specified by ANSI B 16.1-1967. Valves shall be drip-tight in both directions (bi- directional) at rated pressure, 175 psi through 12-inch diameter, 150 psi for 14-inch diameter and above. The valve shall be provided with a 2-inch square operating nut.
4. The valve body shall be constructed of cast iron ASTM A126, Class B. Body ends shall be mechanical joint to meet the requirements of AWWA C1111ANSI A21.11 or single gasket push-on type.
5. The valve plug shall be constructed of cast iron or ductile iron and shall have a conical seating surface which is eccentrically offset from the center of the plug shafts. The plug and shafts shall be integral. The entire plug face shall be totally encapsulated with Buna N (Nitrile) rubber in all valve sizes. The rubber to metal bond must withstand 75 lbs. pull under test procedure ASTM D-429-73, Method B. When the plug is in full open position, plug geometry and body waterway contours must provide a passageway that allows flow capacity equal to 100% of the adjacent pipe area.
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6. Valve seat mating surface shall be constructed of a welded-in overlay of not less than 90% nickel or be a one-piece 304 stainless steel ring. Seat ring contour must be precision machined.
7. A mechanical "brake" shall be supplied on all valves and shall be capable of "locking" the valve in any intermediate position between full-open and full-closed.
8. Valves shall have multiple V-type packing and packing glands and shall be capable of being field adjusted or repacked without the bonnet or plug being removed from the valve with the valve under the full rated pressure. Valves shall have a port position indicator.
9. For corrosion protection, the interior ferrous surfaces of all plug valves shall have a 2- part epoxy internal coating to a minimum of 20 mils thickness.
10. Valve shaft seals shall be adjustable and comply with AWWA C507 Section 10 and with AWWA C507 Section 11.
11. Manual valves shall have lever or gear actuators and tee wrenches, extension stems, floorstands, etc. as indicated on the plans. All valves 6" and larger shall be equipped with gear actuators. All gearing shall be enclosed in a semi-steel housing and be suitable for running in a lubricant with seals provided on all shafts to prevent entry of dirt and water into the actuator. All actuator shafts shall be supported on permanently lubricated bronze bearings. Actuators shall clearly indicate valve position and an adjustable stop shall be provided to set closing torque. All adjustable stop shall be provided to set closing torque. All exposed nuts, bolts, and washers shall be zinc or cadmium plated. Valve packing adjustment shall be accessible without disassembly of the actuator.
12. Valves and gear actuators for submerged service shall have seals on all shafts and gaskets on the valve and actuator covers to prevent entry of water. Actuator mounting brackets for buried or submerged service shall be totally enclosed and shall have gasket seals. All exposed nuts, bolts, springs and washers shall be stainless steel.
13. Three-way plug valves shall be non-lubricated gear oriented. Valve bodies shall be ASTM A 126 Class, and be semi-steel with 125 lb. ANSI standard flanges. Plugs shall be resilient faced. Three-way valves shall be 3-way, 3 port 270 degree turn.
14. Plug valves installed such that actuators are 6 feet or more above the floor shall have chain wheels.
15. Where shown on the Drawings, plug valves shall be installed with extended shafts and actuators. Actuators for extended shafts shall be mounted on floor stands where indicated on the drawings or shall be removable handwheels where floor stands are not called for. Six-inch sleeves shall be provided for extended shafts in all floors; where necessary covers shall be provided. Shafts shall be of adequate strength to operate the valve and shall be 304 stainless steel where submerged and carbon steel elsewhere. Floor stands and covers, where called for shall be cast iron. Floor stands shall be equipped with valve position indicators. Where shown on the drawings, plug valves shall be furnished with extended bonnets, equal to DeZurik Figure 640.
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16. All buried plug valves shall have a remote position indicator in the valve box showing position of the valve. A stainless steel centering and I.D. plate shall be provided showing direction of opening and number of turns to open for each valve.
C. Valves for Buried Service
1. Valves for buried service shall meet all the requirements as specified herein for interior except that buried valves shall have mechanical joint ends.
2. All buried valves shall have cast-iron three piece valve boxes, valve boxes shall be provided with suitable heavy bonnets to extend to such elevation at the finished grade surface as directed by the ENGINEER. The barrel shall be two-piece, screw type, having 51" shaft. The upper section shall have a flange at the bottom having sufficient bearing area to prevent settling, shall be designed so as to prevent the transmission of surface loads directly to the valve or piping, and shall be complete with cast iron covers. Covers shall have "SEWER" cast into the top. The covers shall be so constructed as to prevent tipping or rattling. Valve boxes shall be manufactured by OPELIKA FOUNDRY COMPANY, Opelika, Alabama or TYLER PIPE DIVISION, Tyler, Texas or approved equal.
3. One tee-handled gatewrench of suitable length shall be furnished to operate each valve with a valve box.
4. Where valves are located out of pavement, the boxes shall be adjusted to finished grade and a concrete slab two feet square and six inches thick shall be poured around the box.
5. Valve boxes shall be of the heavy duty, traffic bearing cast iron, adjustable screw type with a drop cover. The valve box assembly shall consist of a bottom section, top section and cover which is cast from gray iron, formulated to ASTM specification A48 latest revision, class 30 minimum and shall be free from blowholes, shrinkage or other imperfections not true to pattern. The shaft size shall be 5 1/4" and the adjustable length shall be from 18" to 24". The wall thickness shall be 3/16" + 1/16". The weight of the assembly shall be 61 pounds + 2 pounds, with the cover weight being a minimum of 12 pounds.
6. The name of the manufacturer and foundry of origin shall be cast into each of the components of the assembly in legible form. The assembly shall be suitable for highway traffic wheel loads of 16,000 pounds and shall withstand a proof load test of 25,000 pounds without failure or permanent deflection, as per Federal Specification RR-F-621- C, latest revision. The valve box shall be cast, machined, assembled, and packaged within the United States and shall fully comply with the Buy American provisions of Public Law 102-240, enacted 12/18/91.
D. Check Valves
1. Check valves smaller than 10 cm (4") shall have a bronze body with a bronze disk. Check valves shall absolutely prevent the return of water back through the valve when the inlet pressure decreases below the delivery pressure. The valve must be full opening, tight seating and its seat right shall be renewable and must be securely held in place by a threaded joint; the valve disc shall be bronze and shall be suspended from a non-corrosive shaft which will pass through a stuffing box. 5000-79695 15110-4 Florida Governmental Utilities Authority Waterway Estates Interconnect 60% Submittal
2. The check valve 10 cm (4") and larger shall be a rubber flapper type swing check valve and the body and cover shall be cast iron construction meeting ASTM A 126 Class B or ductile iron construction. The flapper shall be Buna-N having an "0" ring seating edge and be internally reinforced with steel.
3. Flapper to be captured between the body and the body cover in a manner to permit the flapper to flex from closed to full open position during flow through the valve. Flapper shall be easily removed without need to remove valve from line. Check Valves to have full pipe size flow area. Seating surface to be on a 45° angle requiring the flapper to travel only 35' from closed to full open position, for minimum head loss and non-slam closure.
4. Non-slam closing characteristic shall be provided through a short 35° disc stroke and a memory flex disc return action.
5. When essential to create backflow through the check valve, i.e.; to prime or backflush a clogged pump, an external backflow device shall be included.
6. Valve exterior to be painted Phenolic Primer Red Oxide for high resistance to corrosion.
7. For corrosion protection, the interior ferrous surfaces of all check valves used in sewage applications shall be coated with a factory applied, two-part epoxy coating to a minimum of 20 mils thick.
8. Materials of construction shall be certified in writing to conform to A.S.T.M. specified above.
9. Valve shall be APCO Series 100 Rubber Flapper Swing Check Valve, as manufactured by Valve & Primer Corporation, Schaumburg, Illinois, U.S.A. or series 500 Swing Flex Valve as manufactured by Val-Matic Valve and Manufacturing Corporation or approved equal.
10. All valves shall have a three year 100% replacement guarantee.
E. Pinch Check Valves
1. Pinch check valves smaller than 10 cm ( 4") shall be Red Valves Series 2633 Buna N in a Stainless Steel body with Stainless Steel end connectors or approved equal.
2. Pinch check valves 10 cm (4") and larger shall be Red Valves Series 33 Buna N in an aluminum body or approved equal.
F. Air Release Valves
1. Air release valves (ARV) used on sewer force mains shall be of the automatic type designed for wastewater applications. The valve body shall be cast iron construction, ASTM A 126, Class B, and all internal working parts shall be 316 Series stainless steel, and BUNA-N orifice button. The venting orifice shall be a minimum of 2.54 cm (1") in diameter. The inlet openings shall be sized per manufacturer's recommendation but no less than 5 cm (2") NPT screwed connection. ARVs shall be manufactured by Vent-o-mat
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Series RGX 316 Series stainless steel, or Bermad Flow Control Accessories 300 Series stainless steel air release valves ARI-5-022.
2. The Bermad Flow Control Accessories model ARI D-40 combination valve shall be installed to release air from the discharge piping at the pump station. This valve shall be located as shown in Section 9 of the Lee County Utilities Operations Manual, just past the 90 degree bend on the header pipe detail. The working pressure shall be 200 psi minimum and shall have a 2-inch threaded connection. Air discharged from this valve shall be released through connecting 2 inch PVC or HDPE pipe back through into the wetwell.
G. Corporation Stops
1. Corporation stops for connections to ductile iron or steel piping shall be all brass or bronze suitable for 150 psi test pressure and similar to Mueller Co. H-15029 or equal by Clow Corp.
H. Flange Adapter Couplings
1. Flange adapter couplings shall be of the size and pressure rating required for each installation and shall be suitable for use on either cast iron or ductile iron pipe. They shall be similar or equal to Dresser Company, Style 128. All couplings shall have a sufficient number of factory installed anchor studs to meet or exceed the test pressure rating for this project, 100 psi minimum.
I. Flexible Couplings:
1. Flexible couplings shall be either the split type or the sleeve type as shown on the Drawings.
a. Split type coupling shall be either the split type or the sleeve type as shown on the Drawings. The couplings shall be mechanical type for radius groove piping. The couplings shall mechanically engage and lock grooved pipe ends in a positive coupling and allow for angular deflection and contraction and expansion.
b. Couplings shall consist of malleable iron, ASTM Specification A47, Grade 32510 housing clamps in two or more parts, a single chlorinated butyl composition sealing gasket with a "c" shaped cross-section and internal sealing lips projecting diagonally inward, and two or more oval track head type bolts with hexagonal heavy nuts conforming to ASTM Specification A 183 and A 194 to assemble the housing clamps. Bolts and nuts shall be Series 300 stainless steel.
c. Victaulic type couplings and fittings may be used in lieu of flanged joints. Pipes shall be radius grooved as specified for use with the Victaulic couplings. Flanged adapter connections at fittings, valves, and equipment shall be Victaulic Vic Flange Style 741, equal by Gustin-Bacon Group, Division of Certain-Teed Products, Kansas City, Kansas, or equal.
d. Sleeve type couplings shall be used with all buried piping. The couplings shall be of steel and shall be Dresser Style 38, Smith Blair Style 413, Baker Allsteel, or equal. The coupling shall be provided with stainless steel bolts and nuts unless indicated otherwise. 5000-79695 15110-6 Florida Governmental Utilities Authority Waterway Estates Interconnect 60% Submittal
e. All couplings shall be furnished with the pipe stop removed.
f. Couplings shall be provided with gaskets of a composition suitable for exposure to the liquid within the pipe.
g. If the Contractor decides to use victaulic couplings in lieu of flanged joints, he shall be responsible for supplying supports for the joints.
J. Diaphragm Seals:
1. Diaphragm seals shall be installed on pressure gauge connection to all lines where shown on the Drawings, to protect pressure switches used to monitor excessive pressures on pipe lines. The diaphragm shall be "thread attached" to both piping and pressure switches. Diaphragm seals shall be constructed of cadmium plated carbon steel, except for the lower housing which shall be specifically chosen according to the fluid pressure being monitored.
2. Diaphragm seals shall have a flushing connection and be Type SB Mansfield and Green; No. 877 Trerice; Ashcroft; or equal.
K. Unions
1. Unions on ferrous pipe 2" in diameter and smaller shall be 150 pounds malleable iron, zinc-coated. Unions on water piping 21" in diameter and larger shall be flange pattern, 125 pound class, zinc-coated. Gaskets for flanged unions shall be of the best quality fiber, plastic, or leather. Unions shall not be concealed in walls, ceilings, or partitions.
L. Mechanical Type Seals
1. Mechanical type seals shall consist of an adjustable modular bolted, synthetic rubber and plastic sealing element. The sealing element shall e Link-Seal LS-300-C as manufactured by Thunderline Corp., Inkster, Michigan or approved equal.
M. Hose End Faucets
1. Hose end faucets for potable water supply at submersible stations shall be Zurn Model Z:1385. Faucet shall be furnished with removable key and shall be lockable.
N. Pressure Gauges
1. Each pressure gauge shall be direct mounted, cast aluminum case, with a 41" diameter dial and furnished with a clear glass crystal window, 3/8" shut-off valve, and a bronze pressure snubber. Provide diaphragm seals between shut-off valve and pressure gauge on all sludge and lines with non clear matter in suspension of solution. All gauges shall be weatherproofed. The face dial shall be white finished aluminum with jet black graduations and figures. The face dial shall indicate the units of pressure being measured (e.g., feet, inches, etc.) or be dual scale.
2. If shown on the drawings, each pump discharge line shall be furnished with gauges sized 0-100 psi. 5000-79695 15110-7 Florida Governmental Utilities Authority Waterway Estates Interconnect 60% Submittal
O. Reduce Pressure Backflow Preventor
1. If shown on the drawings, backflow preventors shall be supplied at each pump station.
P. Flow Meters
1. Meters shall be of the magnetic type with Teflon lining, stainless steel electrodes and ultrasonic cleaning, or the universal venturi type with flanged cast or ductile iron body and bronze throat. Flow meters shall be designed to record both the peak pumping station capacity and anticipated minimum flows with equally high accuracy. The meters shall be direct reading in gallons per minute, totalizing in million gallons per day and recording on 12-inch diameter, 24-hour linear charts in gallons per minute. All meters shall also be tied to the Radio Telemetry SCADA System. The flow metering system shall be installed within the pumping station structure, if space is available, or in an exterior protected and drained pit. In all cases, meter by-pass valves and piping shall be provided.
2. Flow meters shall be provided for all sewage pumping stations with ultimate ratings greater than 1500 gpm, or as directed by LCU.
PART 3 EXECUTION
3.1 INSTALLATION
A. All valves and appurtenances shall be installed in the locations shown, true to alignment and rigidly supported. Any damage to the above items shall be repaired to the satisfaction of the ENGINEER before they are installed.
B. Valves shall be carefully inspected, opened wide and then tightly closed and the various nuts and bolts shall be tested for tightness. Special care shall be taken to prevent any foreign matter from becoming lodged in the valve seat. Valves, unless shown otherwise shall be set with their operator shaft vertically. Any valve that does not operate correctly shall be removed and replaced.
C. Valve boxes shall be carefully centered over the operating nuts of the valves so as to permit a valve wrench or key to be fitted easily to the operating nut. Valve boxes shall be set to conform to the level of the finished surface and held in position by a ring of concrete placed under the support flange as shown on the details in Section 9 of the Lee County Utilities Operations Manual. The valve box shall not transmit surface loads to the pipe or valve. Care shall be taken to prevent earth and other material from entering the valve box. Any valve box which is out of alignment or whose top does not conform to the finished ground surface shall be dug out and reset. Before final acceptance of the work, all valve boxes shall be adjusted to finish grade. Valve operating risers shall be installed with any valves required to ensure that the operating nut is 3D-inches or less from the ground surface.
D. After installation, all valves and appurtenances shall be tested at least 1 hour at the working pressure corresponding to the class of pipe, unless a different test pressure is specified. If any joint proves to be defective, it shall be repaired to the satisfaction of the ENGINEER.
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E. Install all floor boxes, brackets, extension rods, guides, the various types of operators and appurtenances as shown on the Drawings that are in masonry floors or walls, and install concrete inserts for hangers and supports as soon as forms are erected and before concrete is poured. Before setting these items, check all plans and figures which have a direct bearing on their location and he shall be responsible for the proper location of these valves and appurtenances during the construction of the structures.
F. Pipe for use with flexible couplings shall have plain ends as specified in the respective pipe sections in Division 15.
G. Buried flanged or mechanical joints shall be made with Series 300, stainless steel bolts. All exposed bolts shall be made with Series 300 stainless steel bolts.
H. Prior to assembly of split couplings, the grooves as well as other parts shall be thoroughly cleaned. The ends of the pipes and outside of the gaskets shall be moderately coated with petroleum jelly, cup grease, soft soap or graphite paste, and the gasket shall be slipped over one pipe end. After the other pipe has been brought to the correct position, the gasket shall be centered properly over the pipe ends with the lips against the pipes. The housing sections then shall be placed. After the bolts have been inserted, the nuts shall be tightened until the housing sections are firmly in contact, metal-to-metal, without excessive bolt tension.
I. Prior to the installation of sleeve-type couplings, the pipe ends shall be cleaned thoroughly for a distance of 8". Soapy water may be used as a gasket lubricant. A follower and gasket, in that order, shall be slipped over each pipe to a distance of about 6" from the end, and the middle ring shall be placed on the already laid pipe end until it is properly centered over the joint. The other pipe end shall be inserted into the middle ring and brought to proper position in relation to the pipe already laid. The gaskets and followers shall then be pressed evenly and firmly into the middle ring flaires. After the bolts have been inserted and all nuts have been made up finger-tight, diametrically opposite nuts shall be progressively and uniformly tightened all around the joint, preferably by use of a torque wrench of the appropriate size and torque for the bolts.
3.2 SHOP PAINTING
A. Ferrous surfaces of valves and appurtenances shall receive a coating of rust-inhibitive primer. All pipe connection openings shall be capped to prevent the entry of foreign matter prior to installation.
3.3 FIELD PAINTING
A. All metal valves and appurtenances specified herein and installed in valve and meter pits will be painted as specified in Section 09900.
3.4 INSPECTION AND TESTING
A. Completed pipe shall be subjected to hydrostatic pressure test for hours at full working pressure. All leaks shall be repaired and line retested as approved by the ENGINEER. Prior to testing, the gravity pipelines shall be supported in an approved manner to prevent movement during tests.
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END OF SECTION
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SECTION 16000
ELECTRICAL - GENERAL PROVISIONS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required and install complete and make operational, electrical and process instrumentation systems for the Waterway Estates Interconnect project in Lee County, FL as shown on the Drawings and as specified herein.
B. The work shall include furnishing, installing and testing the equipment and materials specified in other Sections of the Division 16 Specifications and shown on the Drawings.
C. The work shall include furnishing and installing the following:
1. Electrical service from the Power Company.
2. Conduit, wire and field connections for all motors, motor controllers, control devices, control panels and electrical equipment furnished under other Divisions of these specifications.
3. Conduit, wiring and terminations for all field-mounted instruments furnished under other Divisions of these specifications, including process instrumentation primary elements, transmitters, local indicators and control panels. Lightning and surge protection equipment wiring at process instrumentation transmitters. Install vendor furnished cables specified under other Divisions of these specifications.
4. A complete raceway system for the Data Highway Cables and specialty cable systems. Install the Data Highway Cables and other specialty cable systems [furnished under Division 13] in accordance with the system manufacturers' installation instructions. Review the raceway layout, prior to installation, with the computer system supplier and the cable manufacturer to ensure raceway compatibility with the systems and materials being furnished. Where redundant cables are furnished, install cables in separate raceways.
5. Conduit, wiring and terminations for variable frequency drives, harmonic filters, transformers and power factor correction capacitors furnished under other Divisions of these specifications.
6. Furnish and install precast manholes, precast handholes and light pole bases.
7. Furnish and install manhole and handhole frames and covers.
8. It is the intent of these Specifications that the electrical system shall be suitable in every way for the service required. All material and all work which may be reasonably implied as being incidental to the work of this Section shall be furnished at no extra cost.
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9. Coordinate the sequence of demolition with the sequence of construction to maintain process operation in each area. Remove and demolish equipment and materials in such a sequence that the existing and proposed process will function properly with no disruption of treatment.
D. Each bidder or their authorized representatives shall, before preparing their proposal, visit all areas of the existing site, buildings and structures in which work under this Division is to be performed and inspect carefully the present installation. The submission of the proposal by this bidder shall be considered evidence that their representative has visited the site, buildings and structures and noted the locations and conditions under which the work will be performed and that he/she takes full responsibility for a complete knowledge of all factors governing his/her work.
E. Provide all electrical demolition work associated with the removal of equipment from the existing facilities, including disconnecting and removing all electrical wiring and conduit to equipment being removed under other sections. Survey the existing electrical systems with representatives from other trades prior to performing any demolition work. Identify all conduit and equipment to be removed with tags or paint.
F. All power interruptions to electrical equipment shall be at the Owner's convenience with 72 hours (minimum) notice. Each interruption shall have prior approval.
G. The Contractor shall maintain the existing process in operation at all times. Temporary power connections as required shall be provided by the Contractor at no additional expense to the Owner. All temporary wiring shall be in accordance with the NEC. Any temporary equipment feeders (480V) shall be installed in conduit. The Contractor shall provide to the Engineer details, methods, materials etc. prior to making temporary connections. Furnish and install all equipment and materials including control equipment, motor starters, branch and feeder circuit breakers, panelboards, transformers, etc., for temporary power.
H. Field verify all existing underground electrical conduit, concrete duct banks, manhole, pull boxes, etc. and mechanical piping. The Contractor shall include in his bid all costs associated with relocation or removal of underground equipment as required for construction of the new facilities.
I. The Contractor shall prepare and furnish electrical and instrumentation conduit layout shop drawings for yard electrical, within and under all roads, buildings and structures to the Engineer for approval prior to commencing work. Layouts shall include but not be limited to equipment, pull boxes, manholes, conduit routing, dimensioning, methods and locations of supports, reinforcing, encasement, materials, conduit sizing, equipment access, potential conflicts, building and yard lighting, and all other pertinent technical specifications for all electrical and instrumentation conduits and equipment to be furnished. All layouts shall be drawn to scale on 24 x 36 sheets. Refer to the SUBMITTALS paragraph within this specification for additional requirements.
J. The work shall include complete testing of all equipment and wiring at the completion of work and making any minor correction changes or adjustments necessary for the proper functioning
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of the system and equipment. All workmanship shall be of the highest quality; substandard work will be rejected.
K. A single manufacturer shall provide electrical distribution equipment: switchgear, motor control centers, transformers, disconnect switches, unit substations, panel boards, etc.
L. Contractor shall provide their own temporary power for miscellaneous power (drills, pumps, etc.). No facility circuits shall be used unless approved in writing by the Engineer. Any temporary added shall be removed at job completion.
M. Complete coordination with other contractors. Contractor shall coordinate with all other contractors’ equipment submittals and obtain all relevant submittals.
N. Mount transmitters, process instruments, operator stations, etc. furnished under other Divisions of these specifications.
O. Excavation, bedding material, forms, concrete and backfill for underground raceways; forms and concrete for electrical equipment furnished herein is included in Division 16. All work shall be done in accordance with Divisions 2 and 3 of these specifications.
1.02 RELATED WORK
A. Excavation and backfilling, including gravel or sand bedding for underground electrical work is specified in Division 2.
B. Cast in place concrete work, including concrete encasements for electrical duct banks, equipment pads, light pole bases and reinforcing steel, is specified in Division 3.
1.03 SUBMITTALS
A. Submit to the Engineer, in accordance with Section 01300, shop drawings for equipment, materials and other items furnished under Division 16.
B. Shop drawings shall be submitted for the following equipment:
1. Raceways, Boxes, Fittings and Hangers
2. Wires and Cables
3. Miscellaneous Equipment (as specified in Section 16191)
4. Automatic Transfer Switches
5. Panelboards
6. Lighting Fixtures and Lamps
7. Switches, Receptacles and Covers
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8. Precast Manholes and Handholes, Frames and Covers
9. Grounding Hardware and Connections
10. Diesel Engine Driven Generators
C. Submittals shall be required for the following items:
1. Concealed and buried conduit layouts
2. Test reports
3. Manufacturer’s service reports
D. The manufacturers name and product designation or catalog numbers shall be submitted for the following material utilized:
1. Testing Equipment
2. Ground System Resistance Test Equipment
E. Check shop drawings for accuracy and contract requirements prior to submittal. Shop drawings shall be stamped with the date checked and a statement indicating that the shop drawings conform to the Specifications and the Drawings. This statement shall also list all exceptions to the Specifications and the Drawings. Shop drawings not so checked and noted shall be returned.
F. The Engineer's check shall be for conformance with the design concept of the project and compliance with the Specifications and the Drawings. Errors and omissions on approved shop drawings shall not relieve the Contractor from the responsibility of providing materials and workmanship required by the Specifications and the Drawings.
G. All dimensions shall be field verified at the job site and coordinated with the work of all other trades.
H. Material shall not be ordered or shipped until the shop drawings have been approved. No material shall be ordered or shop work started if shop drawings are marked "APPROVED AS NOTED - CONFIRM", "APPROVED AS NOTED - RESUBMIT" or "NOT APPROVED".
I. In addition to manufacturer's equipment shop drawings, submit electrical installation working drawings containing the following:
1. Concealed and buried conduit layouts, shown on floor plans drawn at not less than 1/4-in = 1-ft-0-in scale. The layouts shall include locations of process equipment, motor control centers, transformers, panelboards, control panels and equipment, motors, switches, motor starters, large junction or pull boxes, instruments and any other electrical devices connected to concealed or buried conduits.
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2. Plans shall be drawn on high quality paper, size 36-in by 24-in and shall be presented in a neat, professional manner.
3. Concrete floors and/or walls containing concealed conduits shall not be poured until conduit layouts are approved.
J. Operation and Maintenance Data
1. Submit operations and maintenance data for equipment furnished under this Division, in accordance with Section 01730. The manuals shall be prepared specifically for this installation and shall include catalog data sheets, drawings, equipment lists, descriptions, parts lists, etc, to instruct operating and maintenance personnel unfamiliar with such equipment.
2. Manuals shall include the following as a minimum:
a. A comprehensive index.
b. A complete "As-Built" set of approved shop drawings.
c. A complete list of the equipment supplied, including serial numbers, ranges and pertinent data.
d. A table listing of the "as left" settings for all timing relays and alarm and trip setpoints.
e. System schematic drawings "As-Built", illustrating all components, piping and electric connections of the systems supplied under this Section.
f. Detailed service, maintenance and operation instructions for each item supplied.
g. Special maintenance requirements particular to this system shall be clearly defined, along with special calibration and test procedures.
h. The operating instructions shall also incorporate a functional description of the entire system, with references to the systems schematic drawings and instructions.
i. Complete parts list with stock numbers, including spare parts.
1.04 REFERENCE STANDARDS
A. Electric equipment, materials and installation shall comply with the latest edition of National Electrical Code (NEC) and with the latest edition of the following codes and standards:
1. National Electrical Safety Code (NESC)
2. Occupational Safety and Health Administration (OSHA)
3. National Fire Protection Association (NFPA)
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4. National Electrical Manufacturers Association (NEMA)
5. American National Standards Institute (ANSI)
6. Insulated Cable Engineers Association (ICEA)
7. Instrument Society of America (ISA)
8. Underwriters Laboratories (UL)
9. Factory Mutual (FM)
10. International Electrical Testing Association (NETA)
11. Institute of Electrical and Electronic Engineers (IEEE)
B. All electrical equipment and materials shall be listed by Underwriter's Laboratories, Inc., and shall bear the appropriate UL listing mark or classification marking. Equipment, materials, etc. utilized not bearing a UL certification shall be field or factory UL certified prior to equipment acceptance and use.
C. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.
1.05 PRIORITY OF THE CONTRACT DOCUMENTS
A. If, during the performance of the work, the Contractor finds a conflict, error or discrepancy between or among one or more of the Sections or between or among one or more Sections and the Drawings, furnish the higher performance requirements. The higher performance requirement shall be considered the equipment, material, device or installation method which represents the most stringent option, the highest quality or the largest quantity.
B. In all cases, figured dimensions shall govern over scaled dimensions, but work not dimensioned shall be as directed by the Engineer and work not particularly shown, identified, sized, or located shall be the same as similar work that is shown or specified.
C. Detailed Drawings shall govern over general drawings, larger scale Drawings take precedence over smaller scale Drawings, Change Order Drawings shall govern over Contract Drawings and Contract Drawings shall govern over Shop Drawings.
D. If the issue of priority is due to a conflict or discrepancy between the provisions of the Contract Documents and any referenced standard, or code of any technical society, organization or association, the provisions of the Contract Documents will take precedence if they are more stringent or presumptively cause a higher level of performance. If there is any conflict or discrepancy between standard specifications, or codes of any technical society, organization or association, or between Laws and Regulations, the higher performance requirement shall be binding on the Contractor, unless otherwise directed by the Engineer.
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E. In accordance with the intent of the Contract Documents, the Contractor accepts the fact that compliance with the priority order specified shall not justify an increase in Contract Price or an extension in Contract Time nor limit in any way, the Contractor's responsibility to comply with all Laws and Regulations at all times.
1.06 ENCLOSURE TYPES
A. Unless otherwise specified herein or shown on the Drawings, electrical enclosures shall have the following ratings:
1. NEMA 1 for dry, non-process indoor locations.
2. NEMA 12 for "DUST" locations.
3. NEMA 4X for outdoor locations, rooms below grade (including basements and buried vaults), "DAMP" and "WET" and “PROCESS” locations.
4. NEMA 4X for "CORROSIVE" locations.
5. NEMA 7 (and listed for use in the area classifications shown) for "Class I Division 1 Group D", "Class I Division 2 Group D" and "Class II Division 1" hazardous locations shown on the Drawings.
1.07 SERVICE AND METERING
A. The power company serving this project is Lee County Electric Cooperative (LCEC). Service will be obtained at 480/277 Volts, 3 Phase, 4 Wire, 60 Hz to the service entrance equipment as shown on the drawings. Contractor shall be responsible to pay all fees and charges as required for temporary/construction power for Contractor’s use. Contractor shall be responsible to pay all fees and charges for permanent service via the bid allowance and submit LCEC invoices to Owner for substantiation. Coordinate with LCEC to provide and meet requirements for these services. LCEC contact is [______], telephone [______], email: [______].
B. Furnish and install the secondary service conduit, wire, connectors, etc. to extend the service(s) to the service entrance main breaker location as shown on the Drawings.
C. The power company will be responsible for the following work:
1. Furnishing and installing the primary overhead conductors and pole line.
2. Furnishing and installing the riser pole, primary cutouts, lightning arresters and grounding.
3. Furnishing and installing primary cables.
4. Furnishing and installing the pole mounted transformers and grounding.
5. Termination of primary cables at primary cables.
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6. Termination of secondary cables at the transformers.
7. Furnishing metering current transformers (C.T.'s), meter and meter wiring.
8. Furnishing meter base and enclosure.
D. The Contractor shall be responsible for the following work:
1. Make all arrangements with the power company for obtaining electrical service, pay all power company charges and furnish all labor and material required for the electrical service.
2. Furnishing secondary conduits and cables from handhole at base of utility power pole to service entrance main breaker.
3. Furnishing and installing a power company approved metering current transformer enclosure.
4. Installing meter base.
5. Furnishing and installing an empty conduit with pull line from the metering C.T. enclosure to the meter enclosure. Conduit size and type shall be approved by the power company.
1.08 HAZARDOUS AREAS
A. Equipment, materials and installation in areas designated as hazardous on the Drawings shall comply with NEC Articles 500, 501, 502, 503, 504 and 510.
B. Equipment and materials installed in hazardous areas shall be UL listed for the appropriate hazardous area classification.
1.09 CODES, INSPECTION AND FEES
A. Equipment, materials and installation shall comply with the requirements of the local authority having jurisdiction.
B. Obtain all necessary permits and pay all fees required for permits and inspections.
1.10 TESTS AND SETTINGS
A. Test systems and equipment furnished under Division 16 and repair or replace all defective work and equipment. Refer to the individual equipment sections for additional specific testing requirements.
B. Make adjustments to the systems and instruct the Owner's personnel in the proper operation of the systems.
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C. In addition to the specific testing requirements listed in the individual Sections, the following minimum tests and settings shall be performed. Submit test reports upon completion of testing in accordance with Section 01300.
1. Mechanical inspection, testing and settings of circuit breakers, disconnect switches, motor starters, overload relays, control circuits and equipment for proper operation.
2. Check the full load current draw of each motor. Where power factor correction capacitors are provided the capacitor shall be in the circuit at the time of the measurement. Check ampere rating of thermal overloads for motors and submit a typed record to the Engineer of the same, including MCC cubicle location and driven load designation, motor service factor, horsepower, and Code letter. If incorrect thermal overloads are installed replace same with the correct size overload.
3. Check power and control power fuse ratings. Replace fuses if they are found to be of the incorrect size.
4. Check settings of the motor circuit protectors. Adjust settings to lowest setting that will allow the motor to be started when under load conditions.
5. Check motor nameplates for correct phase and voltage. Check bearings for proper lubrication.
6. Check rotation of motors prior to testing the driven load. Disconnect the driven equipment if damage could occur due to wrong rotation. If the rotation is incorrect for the driven equipment correct motor connections at the motor terminal box.
7. Check interlocking, control and instrument wiring for each system and/or part of a system to prove that the system will function properly as indicated by control schematic and wiring diagrams.
8. Inspect each piece of equipment in areas designated as HAZARDOUS to ensure that equipment of proper rating is installed.
9. Verify all terminations at transformers, equipment, panels and enclosures by producing a 1, 2, 3 clockwise rotation on a phase sequenced motor when connected to "A", "B" and "C" phases.
10. Verify correct wire termination positions across tie circuits, transfer switches, or other devices that normally have two sources of three-phase power present by performing a hot phase test. That is, in addition to verifying clockwise rotation, a voltage reading across both incoming circuits should measure 0 volts when phase “A” of one side is compared to phase “A” of the other side.
11. Check all wire and cable terminations. Verify to the Engineer connections meet the equipments torque requirements.
12. Field set all transformer taps as required to obtain the proper secondary voltage.
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13. Infra-red hot spot inspection shall be made of all electrical equipment including but not limited to switchgear, motor control centers, transformers, switches, power and control panels, etc. This shall be done under representative load conditions before the equipment is used by the Owner and again 3 months before expiration of the 1-year warranty period.
D. Testing shall be scheduled and coordinated in writing with the Engineer at least 2 weeks in advance. Provide qualified test personnel, instruments and test equipment. Provide certified calibration sheets including dates for all equipment to be used for testing with notice of scheduled testing. Calibration sheets shall also indicate that the units have been calibrated within six months of the testing date. The Contractor shall have qualified personnel present during the testing.]
1.11 INTERPRETATION OF DRAWINGS
A. The Drawings are not intended to show exact locations of conduit runs. Coordinate the conduit installation with other trades and the actual supplied equipment.
B. Install each 3 phase circuit in a separate conduit unless otherwise shown on the Drawings.
C. Unless otherwise approved by the Engineer, conduit shown exposed shall be installed exposed; conduit shown concealed shall be installed concealed.
D. Where circuits are shown as "home-runs" all necessary fittings and boxes shall be provided for a complete raceway installation.
E. Verify the exact locations and mounting heights of lighting fixtures, switches and receptacles prior to installation. Any adjustments required in the field shall be provided at no additional cost to the Owner and coordinated and approved by the Engineer.
F. Except where dimensions are shown, the locations of equipment, fixtures, outlets and similar devices shown on the Drawings are approximate only. Exact locations shall be determined by the Contractor and approved by the Engineer during construction. Obtain information relevant to the placing of electrical work and in case of any interference with other work, proceed as directed by the Engineer and furnish all labor and materials necessary to complete the work in an approved manner.
G. Circuit layouts are not intended to show the number of fittings, or other installation details. Furnish all labor and materials necessary to install and place in satisfactory operation all power, lighting and other electrical systems shown. Additional circuits shall be installed wherever needed to conform to the specific requirements of the approved equipment at no additional cost to the Owner.
H. Redesign of electrical or mechanical work, which is required due to the Contractor's use of an alternate item, arrangement of equipment and/or layout other than specified herein, shall be done by the Contractor at his/her own expense. Redesign and detailed plans shall be submitted to the Engineer for approval. No additional compensation will be provided for changes in the work, either his/her own or others, caused by such redesign.
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I. Surface mounted panel boxes, junction boxes, conduit, etc., shall be supported by ½-inch spacers to provide a clearance between wall and equipment.
J. All floor mounted electrical equipment shall be placed on 4-inch thick (3/4-inch, 45 degree chamfer at all exposed edges) concrete pads, provide reinforcement, anchors, etc.
K. The Contractor shall harmonize the work of the different trades so that interferences between conduits, piping, equipment, architectural and structural work will be avoided. All necessary offsets shall be furnished so as to take up a minimum space and all such offsets, fittings, etc, required to accomplish this shall be furnished and installed by the Contractor without additional expense to the Owner. In case interference develops, the Engineer is to decide which equipment, piping, etc., must be relocated, regardless of which was installed first.
L. Raceways and conductors for lighting, switches, receptacles and other miscellaneous low voltage power and signal systems as specified are not shown on the Drawings. Raceways and conductors shall be provided as required for a complete and operating system. Homeruns, as shown on the Drawings, are to assist the Contractor in identifying raceways to be run exposed and raceways to be run concealed. Raceways shall be installed concealed in all finished spaces and may be installed exposed or concealed in all process spaces. Raceways installed exposed shall be near the ceiling or along walls of the areas through which they pass and shall be routed to avoid conflicts with HVAC ducts, cranes hoists, monorails, equipment hatches, doors, windows, etc. Raceways installed concealed shall be run in the center of concrete floor slabs, above suspended ceilings, or in partitions as required.
1.12 PHASE BALANCING
A. The Drawings do not attempt to balance the electrical loads across the phases. Circuits on motor control centers and panelboards shall be field connected to result in evenly balanced loads across all phases.
B. Field balancing of circuits shall not alter the conductor color coding requirements as specified in Section 16120.
1.13 SIZE OF EQUIPMENT
A. Investigate each space in the structure through which equipment must pass to reach its final location. Coordinate shipping splits with the manufacturer to permit safe handling and passage through restricted areas in the structure.
B. The equipment shall be kept upright at all times during storage and handling. When equipment must be tilted for passage through restricted areas, brace the equipment to ensure that the tilting does not impair the functional integrity of the equipment.
1.14 RECORD DRAWINGS
A. As the work progresses, legibly record all field changes on a set of Project Contract Drawings, hereinafter called the "Record Drawings".
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B. Record Drawings shall accurately show the installed condition of the following items:
1. One-line Diagram(s).
2. Equipment elevations (front views).
3. Raceways and pullboxes.
4. Conductor sizes and conduit fills.
5. Panel Schedule(s).
6. Control Wiring Diagram(s).
7. Lighting Fixture Schedule(s).
8. Lighting fixture, receptacle and switch outlet locations.
9. Underground raceway and duct bank routing.
10. Plan view, sizes and locations of switchgear, distribution transformers, substations, motor control centers and panelboards.
C. Submit a schedule of control wiring raceways and wire numbers, including the following information:
1. Circuit origin, destination and wire numbers.
2. Field wiring terminal strip names and numbers.
D. In addition to the schedule, provide point-to-point connection diagrams showing the same information submitted in the schedule of control wiring raceways including all designations and wire numbers.
E. Submit the record drawings, schedule of control wiring raceways and wire numbers and the point-to-point connection diagrams to the Engineer. The schedule of control wiring raceways and wire numbers and the point-to-point connection diagrams shall be computer generated (i.e. no hand-written or drawn schedules, drawings, or diagrams will be accepted).
1.15 EQUIPMENT INTERCONNECTIONS
A. Review shop drawings of equipment furnished under other Divisions and prepare coordinated wiring interconnection diagrams or wiring tables. Submit copies of wiring diagrams or tables with the Record Drawings.
B. Furnish and install all equipment interconnections.
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1.16 MATERIALS AND EQUIPMENT
A. Materials and equipment shall be new, except where specifically identified on the Drawings to be re-used.
B. Material and equipment of the same type shall be the product of one manufacturer and shall be UL listed.
C. Warrant all equipment furnished under Division 16 in accordance with Section 01740. Refer to individual equipment sections for additional warranty items.
1.17 EQUIPMENT IDENTIFICATION
A. Identify equipment (disconnect switches, separately mounted motor starters, control stations, etc) furnished under Division 16 with the name of the equipment it serves. Motor control centers, control panels, panelboards, transformers, switchboards, switchgear, motors, junction or terminal boxes, transfer switches, etc, shall have nameplate designations as shown on the Drawings.
B. Nameplates shall be engraved, laminated plastic, not less than 1/16-in thick by 3/4-in by 2-1/2-in with high black letters on a white background. Lettering for the major equipment such as identification of the name of motor control centers, switchboards, panelboards, etc. shall be 1-inch high. Lettering for individual starter buckets, feeder breakers, etc. shall be 1/2- inch high. Lettering for individual components such as indicator lights, control stations, relays, etc. shall be 1/4-inch high.
C. Nameplates shall be screw mounted to NEMA 1 enclosures. Nameplates shall be bonded to all other enclosure types using an epoxy or similar permanent waterproof adhesive. Two sided foam adhesive tape is not acceptable. Where the equipment size does not have space for mounting a nameplate, the nameplate shall be permanently fastened to the adjacent mounting surface. Cemented nameplates shall not be drilled.
D. All voltages (e.g. 480 volts, 120 volts, etc.) within pull boxes, junction boxes etc. shall be identified on the front exterior cover. Signs shall be red background with white engraved lettering, lettering shall be a minimum of 1" high.
E. All receptacles, wall switches, lighting fixtures, photo cells, emergency lights, exit lights, etc. shall be identified with the panel and circuit to which it is connected. Identification shall be with machine generated labels with ¼” high letters.
1.18 DEMOLITION
A. Remove electrical work associated with equipment scheduled for demolition except those portions indicated to remain or be reused.
B. Remove unused exposed conduit and wiring back to point of concealment including abandoned conduit above accessible ceiling finishes. Remove unused wiring in concealed conduits back to source (or nearest point of usage).
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C. Disconnect abandoned outlets and remove devices. Remove abandoned outlets if conduit servicing them is abandoned and removed. Provide stainless steel blank covers for abandoned outlets which are not removed.
D. Disconnect and remove abandoned panelboards, transformers, disconnect switches, control stations, distribution equipment, etc.
E. Disconnect and remove abandoned luminaries. Remove brackets, stems, hangers and other accessories.
F. Disconnect electrical circuits in the way of demolition work and re-establish circuits to remaining outlets, fixtures, equipment, etc. Disconnect electrical systems in walls, floors and ceilings scheduled for removal.
G. Provide temporary wiring and connections to maintain existing systems in service during construction. When work must be performed on energized equipment or circuits, use personnel experienced in such operations.
H. New lighting shall be in place or safe lighting levels maintained for plant operation during the construction period.
I. Repair adjacent construction and finishes damaged during demolition and extension work.
J. Where electrical systems pass through the demolition areas to serve other portions of the premises, they shall remain or be suitably relocated and the system restored to normal operation.
K. Coordinate outages in systems with the Owner. Where duration of proposed outage cannot be allowed by the Owner, provide temporary connections as required to maintain service.
L. Removal and relocation of existing conduit, wire and equipment have not been detailed on the Drawings. Survey the affected areas before submitting bid proposal.
M. Trace out existing wiring that is to be relocated, or removed and perform the relocation or removal work as required for a complete operating and safe system.
N. Continuous service is required on all circuits and outlets affected by these changes, except where the Owner will permit an outage for a specific time. Obtain Owner's consent before removing any circuit from continuous service.
O. Remove exposed conduits, wireways, outlet boxes, pull boxes and hangers made obsolete by the alterations, unless specifically designated to remain. Patch surfaces and provide stainless steel blank covers for abandoned outlets which are removed.
P. All equipment, materials, controls, motor starters, branch and feeder breakers, panelboards, transformers, wiring, raceways, etc, furnished and installed to temporarily keep circuits energized shall be removed when the permanent installation is fully operational.
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Q. Electrical Removal
1. All existing electrical equipment and fixtures to be removed shall be removed with such care as may be required to prevent unnecessary damage, to keep existing systems in operation and to maintain the integrity of the grounding systems.
2. Conduits and wires shall be abandoned or removed where shown. All wires in abandoned conduits shall be removed, salvaged and stored. Abandoned conduits concealed in floor or ceiling slabs or in walls, shall be cut flush with the slab or wall at the point of entrance. The conduits shall be suitably plugged and the area repaired in a flush, smooth and approved manner. Exposed conduits and their supports shall be disassembled and removed from the site. Repair all areas of work to prevent rust spots on exposed surfaces.
3. Wall switches, receptacles, and other miscellaneous electrical equipment, shall be removed and disposed of off the site as required. Care shall be taken in removing all equipment so as to minimize damage to architectural and structural members. Any damage incurred shall be repaired.
1.19 DISPOSITION OF REMOVED MATERIALS AND EQUIPMENT
A. In general, it is intended that material and equipment indicated to be removed and disposed of by the Contractor shall, upon removal, become the Contractor's property and shall be disposed of off the site by the Contractor, unless otherwise directed by the Owner. Any fees or charges incurred for disposal of such equipment or materials shall be paid by the Contractor. A receipt showing acceptable disposal of any legally regulated materials or equipment shall be given to the Owner.
B. The following electrical equipment shall be removed and shall be moved by the Contractor to a location on the site for storage as directed by the Owner:
1.20 SAFETY REQUIREMENTS
A. The Contractor shall make every effort to keep all employees and/or subcontractors aware of the danger inherent in working in dangerous proximity to the existing power lines. The minimum recommended precautionary measures are as follows:
1. Make sure that all persons responsible for operating cranes, draglines and other mobile equipment have a copy of, and are familiar with the State Department of Commerce Regulations for Use of Cranes, Draglines and Similar Equipment Near Power Lines, as well as the U.S. Department of Labor OSHA Regulations, before commencing operation of said equipment.
2. Make sure that all cranes, draglines and other mobile equipment have attached to them the black and yellow Department of Commerce warning signs required by the said Regulations of State Department of Commerce.
3. Warn all employees on the ground, new and old employees alike, of the danger of holding on to or touching a cable or other piece of equipment or machinery that is located or working close to any overhead power line.
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4. If, during the course of construction, it becomes necessary for the contractor, or subcontractor, and their employees, to operate cranes, draglines, or their mobile equipment, in dangerous proximity of any overhead power lines, or in such a manner that such equipment might come close to any overhead power lines, the Contractor shall give the Power Company or overhead power line owner prior notice of such proposed operation.]
PART 2 PRODUCTS (NOT USED)
PART 3 EXECUTION
3.01 SLEEVES AND FORMS FOR OPENINGS
A. Provide and place all sleeves for conduits penetrating floors, walls, partitions, etc. Locate all necessary slots for electrical work and form before concrete is poured.
B. Exact locations are required for stubbing-up and terminating concealed conduit. Obtain shop drawings and templates from equipment vendors or other subcontractors and locate the concealed conduit before the floor slab is poured.
C. Where setting drawings are not available in time to avoid delay in scheduled floor slab pours, the Engineer may allow the installations of such conduit to be exposed. Requests for this deviation must be submitted in writing. No additional compensation for such change will be allowed.
D. Seal all openings, sleeves, penetration and slots as specified in Section 16110.
3.02 CUTTING AND PATCHING
A. Cutting and patching shall be done in a thoroughly workmanlike manner and be in compliance with modifications and repair to concrete as specified in Section [01045]. Sawcut concrete and masonry prior to breaking out sections.
B. Core drill holes in existing concrete floors and walls as required.
C. Install work at such time as to require the minimum amount of cutting and patching.
D. Do not cut joists, beams, girders, columns or any other structural members.
E. Cut opening only large enough to allow easy installation of the conduit.
F. Patching to be of the same kind and quality of material as was removed.
G. The completed patching work shall restore the surface to its original appearance or better.
H. Patching of waterproofed surfaces shall render the area of the patching completely waterproofed.
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I. Remove rubble and excess patching materials from the premises.
J. When existing conduits are cut at the floor line or wall line, they shall be filled with grout of suitable patching material.
3.03 INSTALLATION
A. Any work not installed according to the Drawings and this Division or without approval by the Engineer shall be subject to change as directed by the Engineer. No extra compensation will be allowed for making these changes.
B. Electrical equipment shall at all times during construction be adequately protected against mechanical injury or damage by water. Electrical equipment shall not be stored out-of-doors. Electrical equipment shall be stored in dry permanent shelters. If an apparatus has been damaged, such damage shall be repaired at no additional cost. If any apparatus has been subject to possible injury by water, it shall be replaced at no additional cost to the Owner, the damaged unit(s) or systems shall remain on site and returned to the manufacturer after the replacement unit(s) or systems have been delivered to the site. Under no circumstances will electrical equipment damaged by water be rehabilitated or repaired, new equipment shall be supplied and all cost associated with replacement shall be borne by the Contractor.
C. Equipment that has been damaged shall be replaced or repaired by the equipment manufacturer, at the Engineer's discretion.
D. Repaint any damage to factory applied paint finish using touch-up paint furnished by the equipment manufacturer. The entire damaged panel or section shall be repainted per the field painting requirements Section 09902, at no additional cost to the Owner.
3.04 MANUFACTURERS SERVICE
A. Provide manufacturer's services for testing and start-up of the following equipment:
1. Automatic Transfer Switches (____ days ____ trips minimum)
2. Diesel Engine Driven Generator(s) (____ days ____ trips minimum)
3. Variable Frequency Drives (____ days ____ trips minimum)
B. Testing and startup shall not be combined with training. Testing and start-up time shall not be used for manufacturers warranty repairs.
C. The manufacturers of the above listed equipment shall provide experienced Field Service Engineer to accomplish the following tasks:
1. The equipment shall be visually inspected upon completion of installation and prior to energization to assure that wiring is correct, interconnection complete and the installation is in compliance with the manufacturer's criteria. Documentation shall be reviewed to assure that all Drawings, operation and maintenance manuals, parts list and other data required to check out and sustain equipment operation is available on-site.
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Documentation shall be red-lined to reflect any changes or modifications made during the installation so that the "as-built" equipment configuration will be correctly defined. Spare parts shall be inventoried to assure correct type and quantity.
2. The Field Service Engineers shall provide engineering support during the energization and check-out of each major equipment assembly. They shall perform any calibration or adjustment required for the equipment to meet the manufacturer's performance specifications.
3. Upon satisfactory completion of equipment test, they shall provide engineering support of system tests to be performed in accordance with manufacturer's test specifications.
4. A final report shall be written and submitted to the Contractor within fourteen days from completion of final system testing. The report shall document the inspection and test activity, define any open problems and recommend remedial action. The reports after review by the Contractor shall be submitted to the Engineer.
3.05 TRAINING
A. Provide manufacturer's services for training of plant personnel in operation and maintenance of the equipment specified under Division 16.
1. Automatic Transfer Switches (____ days ____ trips minimum)
2. Diesel Engine Driven Generator(s) (____ days ____ trips minimum)
3. Variable Frequency Drives (____ days ____ trips minimum)
B. The cost of training programs to be conducted with Owner's personnel shall be included in the Contract Price. The training and instruction, insofar as practicable, shall be directly related to the system being supplied.
C. Provide detailed O&M manuals to supplement the training courses. The manuals shall include specific details of equipment supplied and operations specific to the project.
D. The training program shall represent a comprehensive program covering all aspects of the operation and maintenance including trouble-shooting of each system.
E. All training schedules shall be coordinated with and at the convenience of the Owner. Shift training may be required to correspond to the Owner's working schedule. The training shall be conducted with record "as-built" drawings sufficient for a class of eight personnel.
F. Within 120 days of contract award to the Contractor, submit an overview of the proposed training plan. This overview shall include, for each course proposed:
1. An overview of the training plan.
2. Course title and objectives.
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3. Prerequisite training and experience of attendees.
4. Recommended types of attendees.
5. Course Content - A topical outline.
6. Course Duration.
7. Course Location - Training center or jobsite.
8. Course Format - Lecture, laboratory demonstration, etc.
9. Schedule of training courses including dates, duration and locations of each class.
10. Resumes of the instructors who will actually implement the plan.
G. The Engineer will review the training plan submittal with the Owner.
END OF SECTION
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SECTION 16110
RACEWAYS, BOXES, FITTINGS AND SUPPORTS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish and install complete raceway systems as shown on the Drawings and as specified herein.
1.02 RELATED WORK
A. Refer to Section 16600 for additional requirements.
1.03 SUBMITTALS
A. Submit to the Engineer, in accordance with Section 01300, the manufacturers' names and product designation or catalog numbers with cut-sheets of all materials specified. Indicate in the submittal, the areas where specific materials are used.
PART 2 PRODUCTS
2.01 MATERIALS
A. Rigid Steel Conduit
1. Rigid steel conduit interior and exterior shall be hot-dipped galvanized and be as manufactured by the Allied Tube and Conduit Corp., Wheatland Tube Co. or equal.
2. Rigid steel conduit shall be galvanized after threading.
3. Rigid steel conduit shall be for use under the provisions of NEC Article 344.
B. PVC Coated Rigid Steel Conduit
1. PVC coated rigid steel conduit shall have a minimum 0.040 in thick, black polyvinyl chloride coating permanently bonded to hot dipped galvanized steel conduit and an internal chemically cured urethane or enamel coating. The ends of all couplings, fittings, etc, shall have a minimum of one pipe diameter in length of PVC overlap. PVC conduit and fittings shall be manufactured by Occidental Coating Company; "Plasti Bond Red" as manufactured by Robroy Industries; Triangle PWC Inc. or equal.
2. PVC coated rigid steel conduit shall be for use under the provisions of NEC Article 344.
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C. Rigid Nonmetallic Conduit
1. PVC conduit shall be rigid polyvinyl chloride schedule 80 as manufactured by Carlon; An Indian Head Co.; Cantex; Queen City Plastics or equal.
2. PVC conduit shall be for use under the provisions of NEC Article 352.
D. Liquidtight Flexible Metal Conduit, Couplings and Fittings
1. Liquidtight flexible metal conduit shall be Sealtite, Type UA, manufactured by the Anaconda Metal Hose Div.; Anaconda American Brass Co.; American Flexible Conduit Co., Inc.; Universal Metal Hose Co. or equal.
2. Fittings used with liquidtight flexible metal conduit shall be of the 3-piece screw-in type malleable iron as manufactured by the O.Z. Gedney Co. or equal.
3. Liquidtight flexible metal conduit shall be for use under the provisions of NEC Article 350.
E. Flexible Couplings
1. Flexible couplings shall be type ECGJH as manufactured by the Crouse-Hinds Co.; Appleton Electric Co.; Killark Electric Manufacturing Co. or equal.
F. Boxes and Fittings
1. Pressed steel switch and outlet boxes shall be hot-dipped galvanized with hot-dipped galvanized tile rings as manufactured by the Raco Manufacturing Co.; Adalet Co.; O.Z. Manufacturing Co. or equal.
2. NEMA 1 and NEMA 12, junction boxes, pull boxes etc., shall be sheet steel unless otherwise shown on the Drawings. Boxes shall be galvanized and have continuously welded seams. Welds shall be ground smooth and galvanized. Box bodies shall be flanged and shall not have holes or knockouts. Box bodies shall not be less than 14 gauge metal and covers shall not be less than 12 gauge metal. Covers shall be gasketed and fastened with stainless steel screws. Terminal boxes shall be furnished with hinged doors, terminal mounting straps and brackets (refer to Section 16191 for additional requirements). Boxes shall be as manufactured by Hoffman Engineering Co.; Lee Products Co.; ASCO Electrical Products Co., Inc., or equal. All boxes shall be shop primed and painted by the box manufacturer.
3. NEMA 4X stainless steel, junction boxes and pull boxes shall be 316 stainless steel with 316 stainless steel hardware and gasketed covers. Boxes shall have continuously welded seams and welds shall be ground smooth. Box bodies shall be flanged and shall not have holes or knockouts. Box bodies shall not be less than 14 gauge metal and covers shall not be less than 12 gauge metal. Covers shall be gasketed and fastened with stainless steel screws. Terminal boxes shall be furnished with hinged doors, terminal mounting straps and brackets (refer to Section 16191 for additional requirements.) Boxes shall be as
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manufactured by Hoffman Engineering Co.; Lee Products Co.; ASCO Electrical Products Co., Inc., or equal.
4. Explosion-proof boxes shall be designed for Class 1, Group D, Division 1 hazardous locations. They shall be cast iron with cadmium-zinc or hot-dipped galvanized finish, stainless steel hardware and bolts; Type EJB as manufactured by the Crouse-Hinds Company; Appleton Electric Co.; The Pyle-National Co. or equal.
5. Cast malleable iron device boxes shall be Type FD. All cast malleable iron boxes and fittings shall have cadmium-zinc finish with cast covers and stainless steel screws as manufactured by the Crouse-Hinds Co. or equal.
6. Cast malleable iron fittings (C's, T's, LB's, etc.) shall be of the mogul design (with rollers) as manufactured by Appleton Electric Co.
7. Conduit hubs shall be of the grounding type as manufactured by Myers Electric Products, Inc. or equal.
8. Conduit wall seals for new concrete walls below grade shall be O.Z./Gedney Co., Type WSK; Spring City Electrical Manufacturing Co., Type WDP or equal.
9. Conduit wall seals for cored holes shall be Type CSML as manufactured by the O.Z./Gedney Co. or equal.
10. Conduit wall and floor seals for sleeved openings shall be Type CSMI as manufactured by the O.Z./Gedney Co. or equal.
11. Combination expansion-deflection fittings embedded in concrete shall be Type XD as manufactured by the Crouse-Hinds Co.; O.Z./Gedney Co.; Spring City Electrical Mfg. Co. or equal.
12. Combination expansion-deflection fittings installed exposed shall be Type XJ as manufactured by Crouse-Hinds Co.; O.Z. Gedney Co.; Spring City Electrical Mfg. Co. or equal.
13. Explosion proof fittings shall be as manufactured by the Crouse-Hinds Co.; Appleton Electric Co.; O.Z./Gedney Co. or equal.
14. Conduit sealing bushings shall be O.Z./Gedney, Type CSB or equal.
15. Steel elbows and couplings shall be hot-dipped galvanized.
G. Conduit Mounting Equipment
1. In dry indoor non-process areas, hangers, rods, backplates, beam clamps, channel, fasteners, anchors, nuts, washers, etc., shall be hot-dipped galvanized steel.
2. 304 Stainless steel channel with 304 stainless steel hardware (hangers, rods, backplates, beam clamps, fasteners, anchors, nuts, washers, etc.) shall be used in process areas, as
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shown on the drawings, in areas designated "WET", "DAMP" and "CORROSIVE" on the Drawings and in outdoor locations. All channel and hardware shall be resistant to the chemicals present in the area in which it is used.
3. Expansion anchors (minimum 3/8" diameter) shall be equal to Kwik-Bolt as manufactured by the McCullock Industries, Minneapolis, MI; Wej-it by Wej-it Expansion Products, Inc., Bloomfield, CO; or Kwik-Bolt II as manufactured by the Hilti Fastening Systems, Inc, Tulsa, OK. The length of expansion bolts shall be sufficient to place the wedge portion of the bolt a minimum of 1-in behind the steel reinforcement. Apply anti-seize compound to all nuts and bolts. Supports installed without the approved compound shall be dismantled and correctly installed, at no cost to the Owner.
H. Wall and Floor Slab Opening Seals
1. Wall and floor slab openings shall be sealed with "FLAME-SAFE" as manufactured by the Thomas & Betts Corp.; Pro Set Systems; Neer Mfg. Co.; Specified Technologies, Inc. or equal.
I. Cold Galvanizing Compound
1. Cold galvanizing compound shall be 95% zinc rich paint as manufactured by ZRC Products Company, a Division of Norfolk Corp. or equal.
PART 3 EXECUTION
3.01 RACEWAY APPLICATIONS
A. Except where otherwise shown on the Drawings, or specified, all wiring shall be in rigid galvanized steel conduit.
B. Schedule 80 PVC shall be used underground. Where schedule 80 PVC is used all elbows shall be PVC coated rigid galvanized steel.
C. PVC conduit shall be used for concrete encased underground duct banks except as specified in Paragraph 3.01B above and except as specified in Section 16600.
D. All conduit of a given type shall be the product of one manufacturer.
3.02 BOX APPLICATIONS
A. Unless otherwise specified herein or shown on the Drawings, all boxes shall be metal.
B. Exposed switch, receptacle and lighting outlet boxes and condulet fittings shall be cast malleable iron.
C. Concealed switch, receptacle and lighting outlet boxes shall be pressed steel. Welded seamed boxes will not be permitted.
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D. Terminal boxes, junction boxes and pull boxes shall have NEMA ratings suitable for the location in which they are installed, as specified in Section 16000.
3.03 FITTINGS APPLICATIONS
A. Combination expansion-deflection fittings shall be used where conduits cross structure expansion joints. Refer to Structural Drawings for expansion joint locations. Provide bonding jumpers around fittings.
B. Conduit wall seals shall be used where underground conduits penetrate walls or at other locations shown on the Drawings.
C. Conduit sealing bushings shall be used to seal conduit ends exposed to the weather and at other locations shown on the Drawings.
3.04 INSTALLATION
A. No conduit smaller than 3/4 inch electrical trade size shall be used, nor shall any have more than the equivalent of three 90 degree bends in any one run. Pull boxes shall be provided as required or directed.
B. No wire shall be pulled until the conduit system is complete in all details; in the case of concealed work, until all rough plastering or masonry has been completed; in the case of exposed work, until the conduit system has been completed in every detail.
C. The ends of all conduits shall be tightly plugged to exclude dust and moisture during construction.
D. Conduit supports, other than for underground raceways, shall be spaced at intervals of 8-ft or less, as required to obtain rigid construction.
E. Single conduits shall be supported by means of malleable iron one-hole pipe clamps in combination with malleable iron one-screw back plates, to raise conduits from the surface. Multiple runs of conduits shall be supported on trapeze type hangers with steel horizontal members and threaded hanger rods. The rods shall be not less than 3/8-in diameter. Surface mounted panel boxes, junction boxes, conduit, etc, shall be supported by spacers to provide a minimum of ½-in clearance between wall and equipment.
F. Conduit hangers shall be attached to structural steel by means of beam or channel clamps. Where attached to concrete surfaces, concrete expansion anchors shall be provided.
G. All conduits on exposed work, within partitions and above suspended ceilings, shall be run at right angles to and parallel with the surrounding wall and shall conform to the form of the ceiling. No diagonal runs will be allowed. Bends in parallel conduit runs shall be concentric. All conduit shall be run perfectly straight and true.
H. Conduit terminating in pressed steel boxes shall have double locknuts (malleable iron) and insulated grounding bushings.
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I. Conduit terminating in gasketed enclosures shall be terminated with grounding type conduit hubs.
J. Conduits containing equipment grounding conductors and terminating in sheet steel boxes shall have insulated throat grounding bushings with lay-in type lugs.
K. Conduits shall be installed using threaded fittings unless otherwise specified herein.
L. Liquidtight flexible metal conduit shall be used for all motor terminations, the primary and secondary of transformers, generator terminations and other equipment where vibration is present.
M. Flexible couplings shall be used in hazardous locations for all motor terminations and other equipment where vibration is present.
N. Where conduits pass through openings in walls or floor slabs, the remaining openings shall be sealed against the passage of flame and smoke.
O. PVC conduit to non-metallic and metallic box connections shall be made with sealing rings, with a stainless steel retainer as manufactured by Thomas & Betts Co.
P. Conduit ends exposed to the weather shall be sealed with conduit sealing bushings.
Q. Expansion fittings shall be used on exposed runs of PVC conduit where required for thermal expansion. Installation and number of fittings shall be as provided per the NEC and approved by the PVC conduit manufacturer.
R. All conduit entering or leaving a motor control center, switchboard or other multiple compartment enclosure shall be stubbed up into the bottom horizontal wireway or other manufacturer designated area, directly below the vertical section in which the conductors are to be terminated.
S. Conduit sealing and drain fittings shall be installed in areas designated as NEMA 7.
T. Spare conduits and conduit stubouts for future construction shall be provided with threaded PVC end caps at each end.
U. No unbroken run shall exceed 300 feet in length. This length shall be reduced by 75 feet for each 90 degree elbow.
V. Galvanized steel conduit entering manholes and below grade pull boxes shall be terminated with grounding type bushings and connected to a 3/4" x 10' rod with a #6 bare copper wire.
W. All field cut threads on PVC coated galvanized steel conduit shall be cleaned and painted with cold galvanizing compound before installation.
X. All tools, (benders, threading machines, etc.) used with PVC coated conduit shall be designed and approved by the conduit manufacturer for use with PVC coated conduit. Tools shall not damage the PVC coating of the conduit. No patching of damaged PVC coated conduit will be
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permitted. Any damaged conduit shall be removed and replaced without exception. Strap wrenches shall be used for tightening PVC coated conduits. Pipe wrenches, channel locks, chain wrenches, pliers, etc. shall not be used.
Y. Underground circuits shall be installed directly to the respective motor control centers, lighting panels, etc., except stainless steel pull boxes shall be wall mounted on structures to eliminate excessive bends. With prior written approval, below grade pull boxes may be used. Splices shall not be made in above or below grade pull boxes unless otherwise indicated on the plans and approved in writing by the Engineer.
Z. All conduits shall have a 4-inch concrete housekeeping pad at all slab and grade penetrations. The housekeeping pad shall have 45 degree, 3/4-inch chamfer at all exposed edges.
AA. All field cut threads on galvanized steel conduit shall be cleaned and painted with cold galvanizing compound before installation.
BB. All risers from underground, concrete pads, floors, etc. shall be provided with heat shrink tubing (Raychem Co. or equal) from a point 1 foot-0-inch below bottom of slab or grade to a point not less than 6 inches above grade or surface of slab.
CC. Existing conduits are to be reused only where specifically noted on the drawings. Mandrels shall be pulled through all existing conduits which will be reused and through all new conduits 2-in in diameter and larger prior to installing conductors.
DD. 3/16-in polypropylene pull lines shall be installed in all new conduits noted as spares or designated for future equipment.
EE. Where no size is indicated for junction boxes, pull boxes or terminal cabinets, they shall be sized in accordance with the requirements of NEC Article 314.
FF. Conduits shall not cross pipe shafts, access hatches or vent duct openings. They shall be routed to avoid such present or future openings in floor or ceiling construction.
GG. The use of running threads is prohibited. Where such threads are necessary, a 3-piece malleable iron union shall be used.
HH. Conduits passing from heated to unheated spaces, exterior spaces, refrigerated spaces, cold air plenums, etc, shall be sealed with "Duxseal" as manufactured by Manville or seal fitting to prevent the accumulation of condensation.
II. All field cut ends of hot dipped galvanized mounting channel shall be cleaned and painted with cold galvanizing compound before installation.
JJ. All underground control and instrumentation conduits shall be separated from power conduits by a minimum of 12 inches unless specifically noted otherwise. Crossing of control and instrumentation conduits with power conduits shall be kept to a minimum and where they must cross they shall cross at 90 degree angles.
END OF SECTION
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SECTION 16120
WIRES AND CABLES
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish, install and test all wire, cable and appurtenances as shown on the Drawings and as specified herein.
B. Install data highway, fiber optic, coaxial and I/O cables furnished under Division 13.
1.02 SUBMITTALS
A. Submit to the Engineer, in accordance with Section 01300, samples of proposed wire. Each sample shall have the size, type of insulation and voltage stenciled on the jacket.
B. Approved samples will be sent to the project location for comparison by the Resident Engineer with the wire actually installed.
C. Installed unapproved wire shall be removed and replaced at no additional cost to the Owner.
1.03 DELIVERY, STORAGE AND HANDLING
A. Carefully handle all conductors to avoid kinks and damage to insulation.
PART 2 PRODUCTS
2.01 GENERAL
A. Wires and cables shall be of annealed, 98 percent conductivity, soft drawn copper.
B. All conductors shall be stranded, except that lighting and receptacle wiring may be solid.
C. Except for control, signal and instrumentation circuits, wire smaller than No. 12 AWG shall not be used.
D. All wire of a given type shall be the product of a single manufacturer.
2.02 MATERIALS
A. 600 Volt or Less Wire and Cable
1. Wire for lighting, receptacles, and other circuits not exceeding 150 volts to ground shall be NEC type XHHW. Below grade and underground the wire shall be type XHHW.
2. Wire for circuits over 150 volts to ground shall be NEC type XHHW for sizes 10 AWG and smaller, and shall be NEC type RHW for sizes 8 AWG and larger.
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3. Wire for control circuits shall be #14 AWG minimum NEC type XHHW stranded.
4. Equipment grounding conductors shall be installed in all raceways. Equipment grounding conductors shall be the same NEC type as the phase conductor, green and sized per NEC Table 250.122. Ground grid conductors shall be uninsulated unless shown otherwise on the Drawings.
5. Types XHHW and RHW wire shall be as manufactured by the Southwire Co., Pirelli Cable Corp., Okonite Co., or equal.
6. Multi-conductor control cable shall be stranded, #14 AWG, 600 V, cross-linked polyethylene insulated w/PVC jacket. Type "XLP" as manufactured by the Southwire Co., American Insulated Wire Corp., or equal.
7. Multi-conductor power cable shall be stranded, 600V, cross-linked polyethylene insulated with PVC jacket, Type TC (XLP) with ground as manufactured by Southwire Co., Rockbestos Co., American Insulated Wire Corp., or equal.
2.03 INSTRUMENTATION WIRE
A. Process instrumentation wire shall be twisted pair, 600 V, cross linked polyethylene insulated, aluminum tape shielded, polyvinyl chloride jacketed type "XLP" as manufactured by the Rockbestos Co., or equal.
B. Cable for 4-20 mA instrumentation, potentiometer, RTD and similar analog circuits shall be multi-conductor twisted and shielded.
1. Single pair cable:
a. Conductors: 2 No. 16 AWG stranded and twisted
b. Insulation: XLP
c. Shield: 100 percent tape with drain wire
d. Jacket: PVC with UL and manufacturers identification
2. Three conductor (triad) cable:
a. Conductors: 3 No. 16 AWG stranded and twisted
b. Insulation: XLP
c. Shield: 100 percent tape with drain wire
d. Jacket: PVC with UL and manufacturers identification
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3. Multiple pair cables (where shown on the Drawings):
a. Conductor: Multiple 2 No. 16 AWG stranded and twisted
b. Insulation: XLP
c. Shield: Individual pairs and overall shielded with 100 percent tape and drain wire
d. Jacket: PVC with UL manufacturers identification
2.04 COMMUNICATION CABLE
A. Ethernet cable shall be designed for use with a high-speed (100 Mbps/Gbps) Ethernet communications network. The twisted pair cable shall have nominal impedance of 100 ohms at 1 Mhz and a maximum attenuation of 10 dB per 1000 feet at 1 Mhz. The twisted pair cable shall be plenum rated and shall have a minimum of four 24 AWG solid copper conductor pairs. All RJ-45 terminations on the twisted pair cable shall be done as specified by the manufacturer. Terminations shall provide strain relief on the cable jacket. Strain relief on the wire and/or wire insulation shall not be acceptable. Cable and connections shall meet or exceed Category 6 ratings and upon completion of the network installation, the system shall be tested to Category 6 standards. Category 6 cable shall be as manufactured by Belden, or equal.
2.05 TERMINATIONS AND SPLICES (POWER CONDUCTORS)
A. Unless otherwise indicated on the plans, no splices may be made in the cables without prior written approval of the Engineer. Where splicing is approved, then splicing material shall be approved by the Engineer and cable manufacturer. Splicing materials for all 600 volt splices shall be made with long barrel tin plated copper compression (hydraulically pressed) connectors and insulated with heavy wall heat shrinkable tubing. The conductivity of all completed connections shall be not less than that of the uncut conductor. The insulation resistance of all completed connections of insulated conductors shall be not less than that of the uncut conductor.
B. 600 volt wire lugs shall be tin plated copper, long barrel compression type (hydraulically pressed) for wire sizes No. 8 AWG and larger. Lugs for No. 10 AWG and smaller wire shall be locking spade type with insulated sleeve. Lugs shall be as manufactured by the Thomas and Betts Co., or equal.
2.06 TERMINATION AND SPLICES (CONTROL CONDUCTORS)
A. Unless otherwise indicated on the plans, no splices may be made in the cables without prior written approval of the Engineer. Where splicing is approved, then splicing material shall be approved by the Engineer and cable manufacturer. Splicing materials and installation shall be as required by the Engineer. The conductivity of all completed connections shall be not less than that of the uncut conductor. The insulation resistance of all completed connections of insulated conductors shall be not less than that of the uncut conductor.
B. Termination connectors shall be of the expanded vinyl insulated locking fork-end (upturned leg ends) type as manufactured by Ideal Industries; 3M Co.; Panduit Corp. or equal.
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2.07 TERMINATIONS (INSTRUMENTATION CABLES)
A. Termination connectors shall be of the expanded vinyl insulated locking fork-end (upturned leg ends) type as manufactured by 3M Co.; Panduit Corp. or equal.
2.08 MOTOR CONNECTIONS
A. For wire sizes #8 AWG and larger, long barrel tin plated copper compression (hydraulically pressed) type connections (Burndy Co., or equal) shall be installed on the branch circuit wires and the motor leads. Bolted connections shall utilize products which are rated for vibration applications (bolt, nut and spring washer). All connections shall be insulated with heavy duty heat shrinkable material (Raychem Corp. or equal).
2.09 WIRE AND CABLE MARKERS
A. Wire and cable markers shall be type written, heat shrinkable type as manufactured by the W.H. Brady Co., Thomas & Betts Co., 3M Co., or equal.
B. Wire and cables with diameters exceeding the capacity of the heat shrinkable markers shall be marked with pre-printed, self-adhesive vinyl tapes as manufactured by the W.H. Brady Co., Panduit Corp., or equal.
2.10 WALL AND FLOOR SLAB OPENING SEALS
A. Wall and floor slab openings shall be sealed with "FLAME-SAFE" as manufactured by the Thomas & Betts Corp. or equal.
PART 3 EXECUTION
3.01 INSTALLATION
A. Uniquely identify all wires, cables and each conductor of multi-conductor cables (except lighting and receptacle wiring) at each end with wire and cable markers.
B. Use lubrications to facilitate wire pulling. Pulling compound shall be nontoxic, nonflammable, noncombustible and noncorrosive. The material shall be UL listed and compatible with the cable insulation and jacket.
C. All wire and cable shall be continuous and without splices between points of connection to equipment terminals, except a splice will be permitted by the Engineer if the length required between the points of connection exceeds the greatest standard shipping length available from the manufacturer specified or approved by the Engineer as the manufacturer of the particular item or wire and cable.
D. Seal openings in slabs and walls through which wires and cables pass.
E. Steel fish tapes and/or steel pulling cables shall not be used in PVC conduit runs.
F. Pull cable from direction that requires the least tension.
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G. Feed cable into raceway with zero tension and without cable crossover at raceway entrance.
H. Use a feed-in tube and sheave designed for cable installation. Use sheaves with radii that exceed the cable manufacturer's recommended minimum bending radius.
I. Use a dynamometer and constant velocity power pulling. Velocity should not be less than 15- ft./min or more than 50-ft/min. Do not exceed the cable manufacturer's maximum recommended tension.
J. If cable cannot be terminated immediately after installation install heat shrinkable end caps.
K. Fireproof exposed cables in manholes, vaults, pullboxes, switchgear and other areas not protected by conduit where medium voltage cables are present. Use fire-proofing tape and glass tape in accordance with the manufacturer's instructions. Fire-proofing tape shall be with one half-lapped layer of Scotch Brand 77 Electric Arc and Fireproofing Tape by 3M Corp. or equal. Tape shall be secured with a two-layer band of Scotch Brand 69 Glass Electrical Tape by 3M Corp. or equal over the last wrap.
L. Uniquely identify all cable at supply and receiving ends and in all manholes, handholes or pullboxes. Use embossed brass tags and tywrap fasteners.
M. Hydraulically or manually operated cable benders shall not be used unless approved in writing by the Engineer.
N. Instrumentation cables shall be installed in rigid steel conduits as specified. All circuits shall be installed as twisted pairs or triads. In no case shall a circuit be made up using conductors from different pairs or triads. Triads shall be used wherever three wire circuits are required.
O. Install shielded instrumentation wire from terminal to terminal with no splicing at any intermediate point. Shielded instrumentation wire, coaxial, data highway, I/O and fiberoptic cables shall be run without splices between instruments, terminal boxes, or panels.
P. Terminal blocks shall be provided at all instrument cable junctions, and all circuits shall be identified at such junctions.
Q. Ground shielding on instrumentation wire at one end only as recommended by the instrument manufacturer and isolated at all other locations. Terminal blocks shall be provided for inter-connecting shield drain wires at all junction boxes. Where individual circuit shielding is required, each shield circuit shall be provided with its own terminal block.
R. Install shielded instrumentation wire in conduit and pull boxes that contain only shielded instrumentation wire. Instrumentation cables shall be separated from all other (i.e. power, control, etc.) cables in manholes.
S. All shielded cable terminations at each end shall be provided with heat shrinkable tubing placed over the exposed shield and conductors. The tubing shall extend 1" minimum over the jacket end and extend ½" minimum from the jacket end over the exposed conductors.
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3.02 WIRE COLOR CODE
A. All wire shall be color coded or coded using electrical tape in sizes where colored insulation is not available. Where tape is used as the identification system, it shall be applied in all junction boxes, manholes and other accessible intermediate locations as well as at each termination.
B. The following coding shall be used:
System Wire Color
240/120 Volts Neutral White Single-Phase, 3 Wire Line 1 Black Line 2 Red
208Y/120, Volts Neutral White 3 Phase, 4 Wire Phase A Black Phase B Red Phase C Blue
240/120 Volts Neutral White 3 Phase, 4 Wire Phase A Black delta, center tap Phase B (High) Orange ground on phase Phase C Blue coil A-C
480Y/277 Volts Neutral Gray 3 Phase, 4 Wire Phase A Brown Phase B Yellow Phase C Purple
Control (Individual Conductors) AC Red DC Blue
3.03 FIELD TESTING
A. Test all 600 volt wire insulation with a megohm meter after installation and prior to termination. Make tests at not less than 1000 volts DC. Submit a written test report of the results to the Engineer. Notify Engineer in writing 48 hours prior to testing.
B. Field testing and commissioning shall be done in accordance with the latest revision of the "Acceptance Testing Specifications for Electrical Power Distribution Equipment and Systems" published by the InterNational Electrical Testing Association (NETA Standard ATS-2007) unless otherwise modified by this Section. Minimum wire insulation resistance shall not be less than 250 Megohms.
C. All service conductors shall be tested as in paragraph A above with the Engineer present.
END OF SECTION
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SECTION 16150
MOTORS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. All motors shall be furnished as called for in other Sections of these Specifications and shall be in conformance with the requirements of this section.
1.02 QUALIFICATIONS
A. Routine tests shall be performed on representative motors, and shall include the information described on NEMA MG1-12.54 "Report of Test Form for Routine Tests on Induction Motors". Efficiency shall be determined in accordance with IEEE Publication No. 112, Method B. Power factor shall be measured on representative motors.
1.03 SUBMITTALS
A. Submittal of motor data for acceptance shall include complete nameplate data and test characteristics in accordance with NEMA Standard MG1-12.54 "Report of Test Form for Routine Tests on Induction Motors" and, in addition, the following for motors typical of the units furnished:
1. Efficiency at ½, ¾ and full load
2. Power factor at ½, ¾ and full load
3. Motor outline, dimensions and weight
4. Descriptive bulletins, including full description of insulation system
5. Bearing design data
6. Special features (i.e., space heaters, temperature detectors, etc.)
B. The motor manufacturer shall submit to the Engineer as provided in Section 01300, certified dimension prints showing nameplate data and outline dimensions within three weeks of the date they receive the order.
C. Guarantee: All equipment furnished and installed under this Section shall be guaranteed against defects of workmanship, materials and proper installation for a period of one (1) year from date of acceptance. All such equipment or parts proven defective, due to the above noted causes, shall be replaced in the machines by the Contractor at no expense to the Owner.
D. Provide equipment warranty in accordance with Section 01740.
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1.04 REFERENCE STANDARDS
A. Institute of Electrical and Electronics Engineers (IEEE)
B. National Electrical Manufacturers Association (NEMA)
C. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.
PART 2 PRODUCTS
2.01 GENERAL
A. Unless otherwise noted, all motors ½ through 100 horsepower shall be rated 230/460 volt, 3 phase, 60 Hertz A.C.; motors 125 horsepower and above shall be rated 460 volt, 3-phase, 60 Hertz, and motors below ½ horsepower shall be rated 115/230 volt, 1 phase, 60 Hertz A.C.
B. All motors used with variable frequency drives shall be rated for inverter duty and shall be in accordance with NEMA MG1-2003, Section IV, Part 31.
C. All motors shall be built in accordance with current NEMA, IEEE, ANSI and AFBMA standards. Motors shall be of the type and quality described by this Section and other Divisions of the Specifications, and/or as shown on the Drawings, fully capable of performing in accordance with Manufacturer's nameplate rating, and free from defective material and workmanship.
2.02 RATINGS
A. All motors shall be sufficient size for the duty to be performed and shall not exceed their full- rated load when the driven equipment is operating at specified capacity and over the operational range. Unless otherwise noted, motors driving pumps, blowers, etc. shall not be overloaded at any head or discharge condition. The motor shall not be required to deliver more than its rated nameplate horsepower, at the 1.0 service factor, under any condition of mechanical or hydraulic loading (i.e. although a 1.15 service factor is required, it may not be used under any condition).
B. Each motor shall develop ample torque for its required service throughout its acceleration range at a voltage 10 percent below nameplate rating. Where shown on the Electrical Drawings to be operated on a reduced voltage starter, the motor shall develop ample torque under the conditions imposed by the reduced voltage starting method.
C. All motors shall be continuous time rated suitable for operation in a 40 degrees C ambient unless noted otherwise.
D. Specific motor data such as Hp, rpm, etc., is specified under the detailed specification for the equipment with which the motor is supplied.
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2.03 NAMEPLATES
A. The motor manufacturer's nameplates shall be engraved or embossed on stainless steel and fastened to the motor frame with stainless steel screws or drive pins. Nameplates shall indicate clearly all of the items of information enumerated in NEMA Standard MG1-10.38 or MG1-20.60, as applicable.
2.04 CONDENSATION HEATERS
A. Condensation heaters, where specified herein or under the detailed mechanical specifications shall be of the cartridge or flexible wrap around type installed within the motor enclosure adjacent to core iron. Heaters shall be rated for 120 Volt, single phase with wattage as required. The heater wattage and voltage shall be embossed on the motor nameplate.
2.05 WINDING TEMPERATURE DETECTORS
A. Winding temperature detectors, unless specified otherwise herein shall be a factory installed, embedded, bi-metallic switch type with leads terminating in the main conduit box. This device shall protect the motor against damage from overheating caused by single phasing, overload, high ambient temperature, abnormal voltage, locked rotor, frequent starts or ventilation failure. The switch shall have normally open contacts. Not less than three detectors shall be furnished with each motor.
B. All motors operating with variable frequency drives shall be equipped with winding temperature detectors.
2.06 THREE PHASE INDUCTION MOTORS
A. Unless specifically noted in other Sections of these Specifications, all motors shall be premium efficient type with the minimum efficiencies as listed below:
NEMA Nominal Horsepower Efficiency, %
1-2 84.0 3-5 88.5 7-1/2 89.5 10 90.2 15 91.0 20 92.0 25 92.2 30 92.4 40-50 94.0 60-100 94.5 Over 100 95.0
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2.07 CONSTRUCTION
A. General:
1. All drip-proof and weather protected Type I and Type II motors shall have epoxy encapsulated windings. Totally enclosed motors shall be provided with an upgraded insulation by additional dips and bakes to increase moisture resistance and shall not be encapsulated. Motors for outdoor service shall have vacuum pressure impregnated (VPI) epoxy insulation for moisture resistance. Two speed motors shall be of the two winding type.
2. Squirrel-cage rotors shall be made from high-grade steel laminations adequately fastened together and to the shaft, or shall be cast aluminum or bar-type construction with brazed end rings.
3. All motors shall be of the premium efficiency and high power factor type. All motors shall be the corrosion resistant type conforming to motors designated as “Corro-Duty” by U.S. Motors or equal.
4. Vertical motors shall be hollow or solid shaft as required by the equipment furnished under other Sections of these Specifications.
5. Totally enclosed non-ventilated (TENV) motors shall include the same ratings and accessories as specified for TEFC motors. Explosion-proof motors shall be UL listed and FM approved for Class 1, Division 1 hazardous areas.
B. Low Voltage, Three Phase Motors:
1. Motors shall be of the squirrel-cage induction type. Horizontal, vertical solid shaft, vertical hollow shaft, normal thrust and high thrust types shall be furnished as called for on the Drawings and as specified in other Sections of these specifications. Motors shall be of the type and quality described by these Specifications, and/or as shown on the schedule on the Drawings, fully capable of performing in accordance with Manufacturer's nameplate rating, and free from defective material and workmanship.
2. Motors shall have normal or high starting torque (as required), low starting current (not to exceed 650 percent full load current), and low slip.
3. Unless otherwise specified, motors shall be totally enclosed fan-cooled construction with a 1.15 service factor at the Class B Temperature-Rise.
4. The output shaft shall be suitable for direct connection or belt drive as required.
5. Motors shall have a Class F non-hygroscopic insulation system but shall be limited to Class B Temperature-Rise, at 1.15 service factor.
6. All motors shall have a final coating of chemical resistant corrosion and fungus protective epoxy fortified enamel finish sprayed over red primer over all interior and exterior surfaces. Stator bore and rotor of all motors shall be epoxy coated.
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7. All fittings, bolts, nuts, and screws shall be plated to resist corrosion. Bolts and nuts shall have hex heads.
8. All machine surfaces shall be coated with rust inhibiter for easy disassembly.
9. Conduit box shall be split from top to bottom and shall be capable of being rotated to four 90 degree positions. Synthetic rubber-like gaskets shall be provided between the frame and the conduit box and sealed with a non-wicking, non-hygroscopic insulating material. A frame mounted pad with drilled and tapped hole, not less than 1/4-inch diameter, shall be provided inside the conduit box for motor frame grounding. All motor conduit boxes shall be provided with the correct number of conduit openings sized as indicated on the drawings. Boxes shall be suitably sized for conductor bending and terminations.
10. Totally enclosed motors shall be provided with condensate drain hole and epoxy coated motor windings to protect against moisture.
11. Nameplates shall be stainless steel. Lifting lugs or "O" type bolts shall be supplied on all frames 254T and larger. Enclosures shall have stainless steel screens. Motors shall be protected for corrosion, fungus and insects.
12. Low voltage, three phase motors shall be manufactured by U.S. Motors, Reliance Electric or Baldor.
13. Fractional Horsepower:
a. Fractional horsepower motors shall be rigid, welded-steel, designed to maintain accurate alignment of motor components and provide adequate protection. End shields shall be cast iron or heavy fabricated steel. Windings shall be of varnish- insulated wire with slot insulation of polyester film, baked-on bonding treatment to make the stator winding strongly resistant to heat, aging, moisture, electrical stresses and other hazards.
b. Motor shaft shall be made from high-grade, cold-rolled shaft steel with drive-shaft extensions carefully machined to standard NEMA dimensions for the particular drive connection.
c. For light to moderate loading, bearings shall be quiet all-angle sleeve type with large oil reservoir that prevents leakage and permits motor operation in any position.
d. For heavy loading, bearings shall be carefully selected precision ball bearings with extra quality, long-life grease, and large reservoir providing 10 years normal operation without re-lubrication.
14. Integral Horsepower:
a. Motor frames and end shields shall be cast iron or heavy fabricated steel of such design and proportions as to hold all motor components rigidly in proper position and provide adequate protection for the type of enclosure employed.
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b. Windings shall be adequately insulated and securely braced to resist failure due to electrical stresses and vibrations.
c. The shaft shall be made of high-grade machine steel or steel forging of size and design adequate to withstand the load stresses normally encountered in motors of the particular rating. Bearing journals shall be ground and polished.
d. Rotors shall be made from high-grade steel laminations adequately fastened together, and to the shaft. Rotor squirrel-cage windings may be cast-aluminum or bar-type construction with brazed end rings.
e. Motors shall be equipped with vacuum-degassed anti-friction bearings made to AFBMA Standards, and be of ample capacity for the motor rating. The bearing housing shall be large enough to hold sufficient lubricant to minimize the need for frequent lubrication, but facilities shall be provided for adding new lubricant and draining out old lubricant without motor disassembly. The bearing housing shall have long, tight, running fits or rotating seals to protect against the entrance of foreign matter into the bearings, or leakage of lubricant out of the bearing cavity.
f. Bearings of high thrust motors will be locked for momentary upthrust of 30 percent downthrust. All bearings shall have a minimum B10 life rating of 5 years in accordance with AFBMA life and thrust values.
g. Vertical hollow-shaft motors will have non-reverse ratchets to prevent backspin. Non-reverse ratchets shall be suitable for duty with variable frequency drives.
C. Low Voltage, Single Phase Motors:
1. Single phase motors shall be split-phase and capacitor-start induction types rated for continuous horsepower at the rpm indicated on the drawings or as required by the specifications. Motors shall be rated 115/230 volts, 60 Hertz, single phase, open drip- proof, or totally enclosed fan cooled as indicated on the drawings or as required by the specifications, with temperature rise in accordance with NEMA Standards for Class B insulation.
2. Totally enclosed fan cooled motors shall be designed for severe-duty.
3. Motors shall have corrosion and fungus protective finish on internal and external surfaces. All fittings shall have a corrosion protective plating.
4. Mechanical characteristics shall be the same as specified for polyphase fractional horsepower motors.
PART 3 EXECUTION
3.01 INSTALLATION
A. Motor Connections: All motors shall be connected to the conduit system by means of a short section 18-inch minimum of liquid tight conduit unless otherwise indicated. For all motor connections of No. 4 AWG or larger wire size, the Contractor shall install a grounding
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conductor in the conduit and terminate at main conduit box and at the motor control center or variable frequency drive with approved ground lugs and clamps.
B. Low Voltage: For wire sizes #8 AWG and larger, long barrel tin-plated copper compression (hydraulically pressed) type connections (Burndy Co., or equal) shall be installed on the branch circuit wires and the motor leads. Bolted connections shall utilize products which are rated for vibration applications (bolt, nut and spring washer). All connections shall be insulated with heavy duty heat shrinkable material (Raychem Corp. or equal).
3.02 TESTS AND CHECKS
A. The following tests shall be performed on all motors after installation but before putting motors into service.
1. The Contractor shall megger (1000 volts DC) each motor winding before energizing the motor, and, if insulation resistance is found to be low, shall notify the Engineer and shall not energize the motor. The following table gives minimum acceptable insulation resistance in megohms at various temperatures and for various voltages with readings being taken after one (1) minute of megger test run.
Degrees Winding Temperature Voltage
F C 115 V. 230 V. 460V.
37 3.9 60 108 210 50 10 32 60 120 68 20 13 26 50 86 30 5.6 11 21 104 45 2.4 4.5 8.8 122 50 1 2 3.7 140 60 0.50 0.85 1.6
2. The Contractor shall check all motors for correct clearances and alignment and for correct lubrication, and shall lubricate if required in accordance with Manufacturer's instructions. The Contractor shall check direction of rotation of all motors and reverse connections if necessary. The correction for wrong rotational direction shall be made at the motor.
3. All tests shall meet the requirements of, but not be limited to, IEEE 43, 85 and 112. Efficiency tests for IEEE 112 shall include Method B.
4. The Contractor shall provide to the Engineer a typed list of all motors 1 HP and larger listing the no load motor current and voltage and the full load current and voltage. Any phase current imbalance greater than 10% shall be reported to the Engineer.
B. Field testing and commissioning shall be done in accordance with the latest revision of the "Acceptance Testing Specifications for Electrical Power Distribution Equipment and Systems" published by the InterNational Electrical Testing Association (NETA Standard ATS-2007).
END OF SECTION
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SECTION 16191
MISCELLANEOUS EQUIPMENT
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish and install all miscellaneous equipment as shown on the Drawings and as specified herein.
B. This Section provides the requirements for miscellaneous equipment typically employed in a facility, however, not all components specified in this Section are necessarily utilized on this project.
1.02 SUBMITTALS
A. Submit to the Engineer, in accordance with Section 01300, detailed catalog information or drawings with sufficient detail to determine compliance with the specifications including describing electrical and physical characteristics of all equipment specified.
1.03 REFERENCE STANDARDS
A. Equipment enclosures shall have NEMA ratings suitable for the location in which they are installed, as specified in Section 16000.
PART 2 PRODUCTS
2.01 MATERIALS
A. Disconnect Switches
1. Disconnect switches shall be heavy-duty, quick-make, quick-break, visible blades, 600 Volt, 3 Pole with full cover interlock, interlock defeat and flange mounted operating handle unless otherwise noted. Enclosure type shall be as noted on the drawings. All current carrying parts shall be copper.
2. NEMA 4X enclosures shall be stainless steel.
3. NEMA 7 enclosures shall be cast aluminum.
4. Lugs shall be copper.
5. All exterior hardware shall be stainless steel.
6. Switches shall be as manufactured by Cutler Hammer, Square D Company or General Electric Company.
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B. Manual Motor Starters
1. Manual starters shall be furnished and installed for all typed of single-phase motors. Manual starters shall be non-reversing, reversing or two speed type as required. NEMA sizes shall be as required for the actual horsepower of the motor furnished. Manual starters shall have motor overload protection in each phase. Built-in control stations shall be furnished as required or as shown on the Drawings.
2. NEMA 4X enclosures shall be stainless steel.
3. NEMA 7 enclosures shall be cast aluminum.
4. Manual motor starters shall be as manufactured by Cutler Hammer, Square D Company or General Electric Company.
C. Magnetic Motor Starters
1. Motor starters shall be 2 or 3 Pole, single or 3 Phase as required, 60 Hz, 600 Volt, magnetically operated, full voltage non-reversing unless otherwise shown on the Drawings. NEMA sizes shall be as required for the horsepowers shown on the Drawings.
2. Two speed starters shall be for single or two winding motors as required by the actual motor furnished or as shown on the Drawings.
3. Each motor starter shall have a 120 Volt operating coil, and control power transformer. Starters shall have motor overload protection in each phase. Auxiliary contacts shall be provided as required or as shown on the Drawings. A minimum of one N.O. and one N.C. auxiliary contacts shall be provided in addition to the contacts shown on the Drawings.
4. Overload relays shall be non-adjustable, ambient compensated and manually reset.
5. Control power transformers shall be sized for additional load where required. Transformer secondaries shall be equipped with time-delay fuses.
6. Built-in control stations and indicating lights shall be furnished as specified herein where shown on the Drawings.
7. NEMA 4X enclosures shall be stainless steel.
8. NEMA Type 7 enclosures shall be cast aluminum.
9. Magnetic motor starters shall be as manufactured by Cutler Hammer, Square D Company or General Electric Company.
D. Combination Magnetic Motor Starters
1. Motor starters shall be a combination motor circuit protector and contactor, 2 or 3 Pole, single or 3 Phase as required, 60 Hz, 600 Volt, magnetically operated, full voltage non-reversing unless otherwise shown on the Drawings. NEMA sizes shall be as required for the horsepowers shown on the Drawings. Motor circuit protectors shall be molded
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case with adjustable magnetic trip only. They shall be specifically designed for use with magnetic motor starters. Motor circuit protectors shall be current limiting type, with additional current limiters if required. Combination motor starters shall be fully rated for 22,000 Amps RMS symmetrical.
2. Two speed starters shall be for single or two winding motors as required by the actual motor furnished or as shown on the Drawings.
3. Each motor starter shall have a 120 Volt operating coil, and control power transformer. Starters shall have motor overload protection in each phase. Auxiliary contacts shall be provided as required or as shown on the Drawings. A minimum of one N.O. and one N.C. auxiliary contacts shall be provided in addition to the contacts shown on the Drawings.
4. Overload relays shall be non-adjustable, ambient compensated and manually reset.
5. Control power transformers shall be sized for additional load where required. Transformer secondaries shall be equipped with time-delay fuses.
6. Built-in control stations and indicating lights shall be furnished as specified herein where shown on the Drawings.
7. NEMA 4X enclosures shall be stainless steel.
8. NEMA Type 7 enclosures shall be cast aluminum.
9. Combination magnetic motor starters shall be as manufactured by Cutler Hammer, Square D Company or General Electric Company.
E. Control Stations and Indicators
1. Control stations shall be heavy-duty type, with full size (30.5mm) NEMA 4X or 7 operators, indicators, etc..
2. Indicators shall be full voltage and push-to-test type. Indicators located indoors shall be LED type and indicators located outdoors shall be incandescent lamp type.
3. NEMA 4X enclosures shall be stainless steel.
4. NEMA 7 enclosures shall be cast aluminum.
5. Control stations shall be Square D Company Class 9001, similar by Cutler Hammer or General Electric Company.
F. General Purpose Dry Type Transformers
1. Transformers shall be dry type, two-winding with kVA and voltage ratings as shown on the Drawings.
2. Four full capacity taps shall be furnished, two 2-1/2 percent above and four 2-1/2 percent below rated primary voltage.
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3. Maximum temperature rise shall be 80 degrees C. Windings shall be copper.
4. Transformers shall be built in accordance with ANSI C89.2 and NEMA ST-20.
5. Transformers shall be provided in NEMA 1 enclosures unless otherwise noted on the Drawings or as required by Section 16000. Where a NEMA 4X and/or stainless steel enclosure is required, the transformer shall be of the TENV type.
6. Transformers shall be furnished with hot dipped galvanized mounting hardware. Where a NEMA 4X and/or stainless steel enclosure is required, the hardware shall be 316 stainless steel.
7. Transformers shall be manufactured by the Square D Company or equal.
G. Transformer-Panel Assembly
1. Each Transformer-Panel Assembly (TPA) shall include a main primary breaker, a dry type transformer and a secondary panelboard with main breaker.
2. Enclosures shall be type NEMA 1 enclosures unless otherwise noted on the Drawings or as required by Section 16000. Main primary, secondary, and feeder breakers shall be enclosed with a padlockable hinged door. Where NEMA 3R stainless steel enclosure is required, the hardware shall be 316 stainless steel.
3. Transformers shall be dry type, two-winding with kVA and voltage ratings as shown on the Drawings.
4. Transformer windings shall be copper, 115 degree C rise, epoxy-resin encapsulated with two full capacity taps rated 5 percent below rated primary voltage.
5. Interconnecting wiring between the primary breaker and transformer, transformer and secondary main breaker, and secondary main breaker and distribution section shall be factory installed.
6. Panelboard bus shall be copper.
7. TPA main primary breaker shall have a minimum interrupting rating of 18 kA at 480 volts and shall be sized per manufacturer’s standard for the kVA size.
8. TPA secondary main breaker shall have a minimum interrupting rating of 10 kA at 240 volts and shall be sized per manufacturer’s standard for the kVA size.
9. TPA feeder breakers shall be [plug-on] [bolt-on] type with a minimum interrupting rating of 10 kA.
10. TPA shall be Mini Power-Zone as manufactured by Square D, Mini-Power Center as manufactured by Eaton/Cutler-Hammer, Servicecenter as manufactured by General Electric or Sentron Power Center as manufactured by Siemens.
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H. Lightning and Surge Protection
1. Lightning and surge protection shall be as manufactured by Advanced Protection Technologies or equal. TVSS’s shall be provided as indicated on the Drawings.
2. TVSS devices shall be tested and labeled in accordance with the following standards: ANSI/IEEE C62.41, ANSI/IEEE C62.45, NEMA LS-1, UL 1449, UL 1283 and NEC Article 285.
3. The TVSS shall be UL listed at or above the available fault current level at the point of TVSS application by UL, per UL 1449 latest edition.
4. The TVSS shall be of a parallel design using fact-acting energy protection that will divert and dissipate the surge energy.
5. Each TVSS shall incorporate 200kAIC fusing and shall monitor all modes of protection and provide LED indicator lights to provide positive operational status of each protected phase.
6. Minimum surge current ratings shall be as follows:
a. 150 kA per mode at 480 volt distribution panels, switchgear, switchboards and substations.
b. 80 kA per mode at 480 volt motor control centers.
c. 80 kA per mode at 480 volt branch panels or control panels.
d. 40 kA per mode at 208 or 240 volt three phase or single phase branch panels.
I. Wireway
1. NEMA 1 wireway shall be gasketed painted steel with stainless steel screw covers.
2. NEMA 4X wireway shall be 316 stainless steel with gasketed clamped covers.
3. NEMA 1 wireway shall be Square-Duct as manufactured by the Square D Co.; NEMA 4X shall be Bulletin F-22 as manufactured by the Hoffman Engineering Co. or equal.
J. Control Relays
1. Control relays shall be heavy duty machine tool type, with 10 Amp, 300 Volt convertible contacts. Number of contacts and coil voltage shall be as shown on the Drawings. General use relays shall be Square D Company, Class 8501 Type X, similar by; Cutler- Hammer, Allen-Bradley Company or General Electric Company. Latching relays shall be Square D Company, Class 8501 Type X, similar by; Cutler-Hammer, Allen-Bradley Company or General Electric Company.
2. Time delay relays shall be pneumatic, 600 Volt, 20 Amp contacts, with calibrated knob operated adjustment and numerical time dial. On delay and off delay types and timing
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ranges shall be as shown on the Drawings or as required for proper operation of the actual equipment furnished. Relays shall be Agastat Model 7012 or 7022 or equal.
K. Polyethylene Warning Tape
1. Warning tape shall be 5 mil red polyethylene film, 6-in minimum width. Tape shall be capable of being detected or located by either conductive or inductive location techniques.
2. Warning tape shall be Mutual Industries Part No. 17774 or equal.
L. Terminal Blocks
1. Terminal blocks shall be 600 Volt, channel mounted, with tubular screw and pressure plate.
2. Terminal blocks shall be Bulletin 1492-CA1 as manufactured by the Allen-Bradley Co. or equal.
M. JIC Boxes for GF Receptacles
1. JIC boxes shall be 6-inches x 6-inches x 4-inches aluminum continuous hinge clamp cover boxes, Hoffman Catalog Number A-606 CHAL with Type L23 stainless steel fast operating JIC clamp, or equal.
2. Install 1-1/2-inch bushings in bottom of box for cord and plug to pass through.
N. Corrosion Inhibitors
1. All equipment enclosures, terminal boxes, etc, located in a NEMA 4X rated area (where shown on the Drawings) that contains electrical or electronic equipment or terminal strips shall be furnished with an internally mounted, chemically treated corrosion inhibitor pad.
2. The corrosion inhibitor pads shall be as manufactured by Hoffman Engineering Co.; 3M or equal.
O. Equipment Mounting Stands
1. Equipment mounting stands shall be custom fabricated from 1/4-in 304 stainless steel plate and 3-in 304 stainless steel channel, unless otherwise shown on the Drawings.
2. All hardware shall be 316 stainless steel.
P. Intrinsically Safe Relays
1. Intrinsically safe relays shall be solid state type with 5 Amp output contacts, suitable for use on a 120 Volt, 60 Hz power supply and shall be FM approved for pilot devices in Class I, Division 1, Group D hazardous atmospheres.
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2. Intrinsically safe relays shall be Gems Solid State Safe-Pak as manufactured by Gems Sensors, Division of Transamerica Delaval, Inc. or equal.
Q. Power Monitors
1. Microprocessor based metering: At each circuit location shown on the Drawings, furnish a digital microprocessor based metering device capable of monitoring and displaying the functions listed below. The device shall provide the status input functions indicated and the capability to communicate data to a centralized monitoring system via a data highway network. The device shall be UL listed. The device shall be Power Logic type as manufactured by the Square D Company or equal.
2. Metering Functions
a. The Digital AC Instrumentation Package shall be capable of measuring, calculating and directly displaying on the front panel display the following information:
1) Volts on each phase plus average of all three phases
2) Current on each phase plus average of all three phases
3) Neutral or ground current
4) Frequency
5) Power Factor
6) KVA
7) KVAR
8) KW
9) Total KWH as an accumulating total, providing bi-directional (import/export) indication
10) Total KVARH as an accumulating total, providing bi-directional (import/ export) indication
11) Amps Demand.
3. Monitoring and Control Functions
a. Provide eight self-powered digital status inputs to monitor the following points:
1) Circuit breaker OPEN status
2) Circuit breaker CLOSED status
3) Circuit breaker TRIPPED status
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4) Circuit breaker OUT OF SERVICE (withdrawn) status.
b. Provide one auxiliary analog input rated 1.0 VAC/VDC nominal full scale input which can be used to measure an external variable such as transformer temperature, air temperature, or battery voltage.
c. Provide one auxiliary analog output (selectable 0-20ma or 4-20ma) proportional to any measure parameter.
d. Provide three Form C dry contact control relay outputs rated 277 VAC or 30 VDC at 10 Amp maximum load current, that can each function as:
1) Setpoint relays that operate as a function of any measured parameter for demand, power factor, or load control. Seventeen programmable setpoints shall each have programmable operate and release limits and time delays on operate and release. Relays shall provide selectable pulse mode or tach mode operation.
2) Remote control relays operated by commands via the communications port.
3) Breaker trip relay (over/under volt, volt unbalance, phase reversal, current unbalance, over/under frequency).
4) KWH or KVARH pulse output relay.
5) Alarm relays.
4. Operational Features
a. Provide the following operating features:
1) True RMS measurements.
2) Connect directly to PT's and CT's for systems over 600 volts.
3) Provision for a fourth current input for measurement of ground or neutral current.
4) 300 amp, one second surge protection on all four current inputs.
5) 3-field, 20 character, high visibility 0.4-in character height vacuum-fluorescent display with a programmable time out feature.
b. Store in non-volatile memory the following:
1) A time-stamped alarm and event log of up to 50 events which records event date, time (to 1 second), event type and value for all over/under limit conditions, all status input activity and all relay operations. Log shall be read via the communications port.
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2) A time-stamped minimum/maximum log, which records the value of any parameter exceeding the previous highest or lowest value recorded. Log shall be read from the front panel display or via communication port.
3) A time-stamped snapshot (historical) log, with a 100 snapshot capacity and user-definable snapshot interval from 1 second to 400 days which records snapshot values for Average Volts, Average Amps, KW, KVAR, KW Demand, Power Factor, Frequency, KWH, KWH Reverse, KVARH and Auxiliary Volts Input. Log shall be read via the communications port.
4) All setup data.
5. The device shall be field programmable as follows:
a. Volts scale, volts mode (wye, delta, single phase), amps scale, Vaux scale, baud rate and the relay operation shall be programmable from the front panel.
b. All parameters above, plus additional alarm/event parameters shall be programmable via the communications port using a portable terminal or a computer.
1) The programming shall be password protected.
6. Waveform Capture
a. Provide waveform capture capability allowing any of the eight voltage and current input channels to be digitally sampled at 256 samples/60 Hz cycle. Waveform capture shall be initiated using commands made via the communications port. Waveform capture data shall be mad accessible via the communications port.
7. Data Communications
a. Provide a serial communication port which has:
1) Switchable RS-232C and RS-485 capability.
2) Addressable polling of multiple units.
3) Packet transmission.
4) Selectable transmission at 300 to 19,200 baud.
b. Provide all communication cables to interconnect monitors within the electrical equipment.
c. All necessary cables, connectors, software, hardware, etc. shall be provided as required to interface with a computer system and/or related PLCs as specified herein or in other Sections and Divisions of the specifications.
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R. Main Circuit Breaker Enclosures
1. Service: 480 volt, 3-phase, 3-wire, service entrance rated, 60 Hertz, ampacity as noted on the Drawings.
2. The overall short circuit withstand rating of the equipment and devices shall be 65,000 Amperes R.M.S. symmetrical at 480 volts. Main circuit protective devices shall be fully rated for the specified short circuit duty. Systems employing series connected ratings for main and feeder devices shall not be used. Bus shall be tin plated copper.
3. Circuit Breakers
a. Power circuit breakers: 100 percent equipment rated, 600 volt, insulated case circuit breakers with integral fully adjustable solid state trip device. Trip device shall be temperature insensitive and have the following characteristics and functions:
1) Independently adjustable long time pick-up and delay.
2) Independently adjustable short time pick-up and delay.
3) Adjustable instantaneous.
4) Independently adjustable ground fault pick-up and delay.
5) Trip mode targets for over load, short circuit, and ground fault.
4. Enclosure: NEMA 4X.
5. Manufacturer shall provide ground fault CT's, metering, lightning arresters, etc. as shown on the drawings.
6. Surge protection shall be as specified herein.
7. Main circuit breakers, enclosures, etc., shall be as manufactured by Square D, General Electric, or equal.
S. Automatic Transfer Switch
1. The rating of the automatic load transfer switch shall be 3-phase, 480 volts, 3-pole, with ampacity as noted on the drawings.
2. The automatic transfer switch shall be mechanically held on both the emergency and the normal side, and rated for continuous duty in an unventilated enclosure. The switch shall be double throw with the main contacts rigidly and mechanically interlocked to insure only two possible positions; Normal or Emergency. The transfer switch shall be NEMA 4X stainless steel construction. A manual operator shall be provided to enable manual operation. Two sets of normally closed and open auxiliary switches shall be provided on each breaker in addition to those required for controls.
3. The transfer switch shall be listed under U.L. 1008.
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4. Automatic load transfer switch shall include the following accessories:
a. Engine starting contacts to provide for generator starting (2 sets).
b. Full phase protection. Three phase relays shall be field adjustable, close differential type with 92-95 percent pick-up and 82-85 percent drop-out. Relays are to be connected across live lines.
c. Test switch, to simulate a power outage, mounted external.
d. Adjustable time delay on engine starting to over-ride momentary outages and nuisance voltage dips.
e. Adjustable time delay on transfer of load to emergency source.
f. Adjustable time delay to retransfer to normal source after removing generator from load.
g. Adjustable time delay on retransfer of load to normal with 5 minute cool-down timer wherein the generator set runs unloaded after retransfer to line.
h. Plant exerciser to start and run the generator set without load each 168 hours for a 30 minute interval.
i. One auxiliary contact closed on emergency and four auxiliary contacts open on emergency.
j. Pilot lights to indicate the normal and emergency position of the transfer switch.
k. Isolated (ungrounded) neutral bar.
l. The transfer switch shall be rated for 65,000 AIC.
m. All wiring shall be numbered at each end with type written heat shrinkable markers.
n. Nameplates.
1) Master nameplate
2) Legend plates for identification of pilot devices and controls.
5. The Contractor shall be responsible for providing all necessary wiring between the generator set and the ATS, at no additional cost to the Owner. All materials shall be in accordance with Division 16.
6. Approved Manufacturers: Russelectric, Type RMTD or equal.
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2.02 CONTROL SYSTEM
A. The Manufacturer shall provide a complete and fully functional control system to manually or automatically operate the control system as specified herein and in other applicable sections of these specifications. All Manufacturers recommended safety devices shall be furnished to protect operators. All control devices, unless specified otherwise, shall be mounted in the Control Panel.
B. Control Panel Construction / EcoSmart Panels
1. The control panel shall consist of a main circuit breaker, a motor circuit protector (MCP) and magnetic starter, or circuit breaker and variable frequency drive for each motor, and a 120-volt control power transformer (fused on primary and secondary). All control components shall be mounted in one common enclosure. Control switches shall provide means to operate each motor manually or automatically.
2. Unless specifically noted otherwise, the electrical control equipment shall be mounted within a NEMA 4X enclosure, constructed of not less than 14 gauge 304 stainless steel painted white. Latches shall be quarter turn quick release type and all hardware shall be 316 stainless steel. Where NEMA 3R or 12 enclosures are specifically required, the door shall be provided with a pad-lockable vault type 3-point latch. The enclosure shall be equipped with a door and shall incorporate a removable back panel on which control components shall be mounted. Back panel shall be secured to enclosure with collar studs. Door(s) shall be interlocked with main circuit breaker and provided with pad-locking provision.
3. Enclosure shall be designed to provide adequate heat dissipation of interior electrical components along with solar gain for panel located outdoors.
4. All motor branch circuit breakers, motor starters and control relays shall be of highest industrial quality, securely fastened to the removable back panels with screws and lock washers. Back panels shall be tapped to accept all mounting screws. Self-tapping screws shall not be used to mount any component.
5. A thermal-magnetic air circuit breaker, Type FH as manufactured by the Square D Company, or equal, shall be furnished for the main breaker. All circuit breakers shall be sealed by the manufacturer after calibration to prevent tampering. Each circuit breaker shall be adequately sized to meet the equipment operating conditions. Motor Circuit Protectors (MCP) shall be molded case with adjustable magnetic trip only, "Mag-Gard" as manufactured by the Square D or equal.
6. An open frame, across-the-line, NEMA-rated magnetic motor/starter, Class 8536 as manufactured by the Square D Company, or equal, shall be furnished for each motor. All motor starters shall be provided with motor circuit protectors and equipped to provide under-voltage release and overload protection on all three phases. Motor starter contacts shall be easily replaceable without removing the motor starter from its mounted position. Overloads shall be of the melting alloy or bi-metallic type, adjustable overloads are not acceptable, Class 10 quick trip overloads shall be provided for all submersible motors. Overload reset push-buttons shall be located on the exterior of the door. Normally open and normally closed auxiliary motor overload contacts wired to terminal blocks shall be
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provided for each motor starter within the control panel. Where variable frequency drives are provided, they shall conform to the technical requirements included in Section 16370.
7. Auxiliary contacts shall be provided for remote run indication and indication of each status and alarm condition. Additional controls shall be provided as specified herein and as required by Divisions 13, 16 and as shown on the drawings.
8. All operating control and instruments shall be securely mounted on the exterior door. All controls and instruments shall be clearly labeled to indicate function. All exterior mounted equipment shall be NEMA 4X.
9. Mode selector switches shall be Hand-Off-Auto type to permit override of automatic control and manual actuation of shutdown. Switches shall be NEMA 4X (800H) as manufactured by Allen-Bradley, or equal, providing three (3) switch positions, each of which shall be clearly labeled according to function.
10. Indicator lamps shall be LED (indoors) or Incandescent (outdoors) full voltage type and mounted in NEMA 4X (800H) modules, as manufactured by Allen-Bradley. Lamp modules shall be equipped to operate at 120 volt input. Lamps shall be easily replaceable from the front of the control compartment door without removing lamp module from its mounted position. Indicators shall be provided for individual motor run and an indicator for each failure condition.
11. A six (6) digit, nonreset elapsed time meter shall be connected to each motor starter to indicate the total running time of each motor in "hours" and "tenth of hours". The elapsed time meters shall be Series T50 as manufactured by the ENM Company or equal.
12. A failure alarm with horn and beacon light shall be provided. Silence and reset pushbuttons shall also be furnished. A common failure reset pushbutton shall be provided to reset the alarm conditions (reset shall occur only if fault condition has been cleared). The alarm horn shall be weatherproof rated with gasket (Federal Signal Corporation, Cat. #350 or equal). The alarm beacon shall be NEMA 4X rated, red lense and solid state flasher (Ingam Products Inc. LRX-40).
13. The control panel shall operate on a power supply of 480 volts, 3-phase, 60 hertz unless otherwise noted.
14. The control diagrams and overload tables shall be laminated to the inside of the door except where door space is limited the laminated documents shall be in the print storage pocket.
15. Print storage pockets shall be provided on the inside of each panel. Pocket shall be of sufficient size as required to hold all prints necessary to service the equipment. A set of reduced drawings shall be provided for each panel, fixed to fit in the storage pocket.
16. A duplex GFCI utility receptacle (circuit breaker protected) providing 120 volts, 60 Hertz, single phase current shall be mounted on the side of the enclosure.
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17. The control panel shall include an adjustable time delay relay to prevent any two motors from starting simultaneously. All timing relays shall be solid state, with pin (octal) and bases, relays shall be T-series as manufactured by Diversified Electronics Inc. or equal.
18. Alternators shall be provided to sequence motors, alternators shall be 008-120-13SP or 009-120-23AP as manufactured by Sta-con, or equal.
19. A phase monitor shall be provided for the control panel, monitors shall be model SUA- 440-ASA as manufactured by Diversified Electronics Inc., or equal.
20. All exterior mounted equipment shall be rated NEMA 4X. Hinged NEMA 4X 316 stainless steel viewing windows will be permitted where such equipment is not available with a NEMA 4X rating.
21. The control panel shall be provided with lightning and surge protection. Protection devices shall be mounted within the control panel enclosure. Lead lengths shall not be longer than 12 inches from the main circuit breaker. Protection shall be rated for peak current 80kA per phase, non-modular design. Advanced Protection Technologies series TE/XF or equal. Exact model number per voltage and phase power system used.
22. All control panel wiring shall be numbered at both ends with type written heat shrinkable wire markers.
23. Wiring shall be stranded copper, minimum size #14 AWG (except for shielded instrumentation cable), with 600 volt, 90 degree C, flame retardant, Type MTW thermoplastic insulation.
24. The control panel shall be provided with nameplates identifying each component, selector switches, pilot lights, etc.. Nameplates shall be permanently affixed using an epoxy process (inner door nameplates shall be fastened with stainless steel screws). Nameplates shall be laminated plastic, engraved white letters with a black background.
25. All control panels shall be provided with a master nameplate located on the exterior door.
26. Where applicable provide a nameplate which reads as follows "CAUTION - THIS PANEL CONTAINS A VOLTAGE FROM AN EXTERNAL SOURCE." Letters shall be black on a high visibility yellow background.
27. Corrosion Inhibitor Emitter: Inclusion of an industrial corrosion inhibitor emitter that shall protect internal components of control panel from corrosion for up to one year. One spare emitter shall be provided for each control panel.
28. All control relays shall be have 10 amp rated contacts (minimum), 11 pin with mounting base , 3PDT (minimum), with LED indicators to show relay status, relays shall be manufactured by Potter Brumfield or equal.
29. Terminal blocks shall be 600 volt heavy duty rated, tubular clamp type. Terminal strips shall be Allen Bradley catalog #1492-CA-1 or equal. Each terminal shall be individually labeled.
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30. The completed control panel assembly shall be U.L. certified.
31. Intrinsically safe relays shall be solid state type with 5 amp output contacts, suitable for use on 120 volt, 60 hertz power supply and shall be Factory Mutual approved for devices in Class 1, Division 1 hazardous atmospheres. Intrinsically safe relays shall be Gems Solid State Safe-Pak as manufactured by Gems Sensors, Division of Transamerica Delaval, Inc. or equal.
32. All electronic control equipment (i.e. controllers, isolators, signal boosters, transmitters, PLC's, etc) shall be as specified in Division 13.
33. A copper ground bar with sufficient terminals for all field and panel ground connections shall be provided.
34. All signal wiring entering and exiting the control panel shall be provided with surge protection. Surge protection shall be as specified in Division 13.
35. An 8-inch (minimum) clear space within the enclosure shall be provided horizontally along the entire top and bottom of the control panel. A 4-inch (minimum) clear space within the enclosure shall be provided vertically along the entire sides of the control panel. No devices, terminals, etc. shall be installed within this space, the space shall be provided for field conduit and wiring access only.
36. Incoming phase conductor terminals shall be clearly identified. All wiring within the control panel shall be color coded or coded using electrical tape in sizes where colored insulation is not available. The following coding shall be used.
System Wire Color
Incoming line voltage Phase conductors Black Ground Green Neutral (As Required) White
Less than line voltage AC Red (individual conductors) DC Blue Foreign Yellow
C. Spare Parts
1. The following number of spare parts shall be furnished for each control panel.
a. 1 Indicator light assembly
b. 2 control relays for each type furnished
c. 5 fuses for each type/size furnished
d. 1 set thermal overloads for each size furnished
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e. 1 selector switch for each type furnished
f. 1 starter coil for each size furnished
PART 3 EXECUTION
3.01 INSTALLATION
A. Mounting Stands
1. Field mounted disconnects, pushbutton control stations, etc, shall be mounted on 316 stainless steel stands as specified herein or as shown on the Drawings. Where clearance requirements for stands may not be maintained, the Engineer may direct equipment to be wall-mounted adjacent to the motor or device, but in no case shall the distance from the motor or device to the control station exceed 3-ft.
B. Miscellaneous Equipment
1. Perform tests and adjust as required per Section 16000.
2. Provide and install identification as required per Section 16000.
3. All wiring shall be done in a neat and workmanlike manner.
4. Remove all rubbish and debris from inside and around the equipment. Remove dirt, dust or concrete spatter from the interior and exterior of the equipment using brushes, vacuum cleaner or clean lint-free rags. Do not use compressed air.
END OF SECTION
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SECTION 16217
DIESEL ENGINE DRIVEN GENERATOR (SELF-CONTAINED WITH MODULAR WEATHERPROOF ENCLOSURE AND SUB-BASE FUEL TANK)
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall furnish all labor, materials, equipment and incidentals required and perform all work necessary and design, to complete the manufacture, to make factory tests and field tests as required, to paint as required one complete diesel engine driven emergency generator unit, properly housed for outdoor operation and subject to the terms and conditions of the Contract Documents.
B. The unit shall have a continuous stand by rating (site rated) of not less than 100 kW at 80 percent lagging PF with 480 Volt, 3 Phase, 60 Cycle, 4 Wire alternating current generator complete with excitation system, controls, steel sub-base and all essential and desirable appurtenances whether specifically mentioned in this Section or not. The complete generator unit shall be properly housed for outdoor operation and shall include all items and equipment required for operation.
C. The manufacturer of the new generator shall include all equipment, appurtenances, and installations as required.
D. The unit shall be arranged for automatic starting and stopping and load transfer upon failure of the normal source of power. Parallel operation with the utility company is not required.
E. All equipment and controls specified in this Section shall be new and be considered part of the engine generator package; the engine generator Manufacturer, or his licensee shall be responsible for furnishing the package in its entirety as specified herein. Various components of the package, including wiring and interconnected piping shall be installed by others. However, the engine generator package shall be complete in all respects and shall include all equipment and controls necessary for a fully operational alternative power supply.
F. The equipment to be furnished under this Section includes; but shall not be limited to the following:
1. Main line circuit breaker and protective relays.
2. All required ductwork for an engine driven radiator cooled unit.
3. Entire exhaust system.
4. Fuel system piping, tanks and appurtenances.
5. Skid mounted, factory-piping, wiring and valves.
6. Flexible connectors and/or expansion joints for field piping.
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7. Automatic control valves.
8. Pre-wired control panel for engine instrumentation and alarms.
9. Unit mounted main circuit breaker.
10. Engine mounted electric starters with battery and battery charger.
11. Spring type vibro isolators.
12. Spare parts and special tools.
13. Services of a Manufacturer's representative.
1.02 RELATED WORK
A. Field electric wiring and connections are included in Division 16.
B. Automatic transfer switch is included in Section 16191.
1.03 SUBMITTALS
A. Submit shop drawings and product data shall include the following:
1. Shop drawings, catalog cuts, internal wiring schematics and other materials required to completely describe the systems and equipment being furnished.
2. Identification, description and dimensions for each separately installed sub-assembly or piece of equipment and associated piping and electrical connection schematics.
3. Foundation drawings, indicating size and location of anchor bolts.
4. Performance specifications of all items of equipment.
5. Detailed description of jacket water treatment materials and procedures.
6. Control panel layout drawings showing interior and exterior views, dimensions, paint finish specifications and component bill of materials.
7. Complete electrical, instrumentation, control and wiring diagrams in sufficient detail to allow installation of instrumentation and controls and electrical components. Specifically, the following is required:
a. Complete instrumentation and control schematics, presented in conformance with Instrument Society of America Bulletin S5.1, latest edition and NFPA 79, latest edition.
b. Complete electrical circuit schematics, including all generator control, alarms, and power to motors, accessories, instruments, etc. Schematics shall include all termination points in each control panel. All wiring shall be identified by numbers and every termination point shall be assigned a number. Termination point number
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(including wire number) shall appear on the schematics for each wiring termination shown.
c. Complete external electrical interconnection diagrams for wiring between control panels, switchgear and engine terminal boxes.
8. Complete Operations and Maintenance Manuals, covering all equipment furnished, annotated to reference only the specific model numbers supplied. Include parts lists and parts prices current to the date of submittal; include information relevant to parts supply and ordering. It is essential that this information be received prior to the startup and testing of the engine/generator unit.
B. Design Data
1. Submit design data for engine, generator, and accessories in format indicated in Paragraphs B2 through B12 (For rated kw capacity).
2. Engine Data
a. Manufacturer
b. Model
c. Number and arrangement of cylinders
d. RPM
e. Bore x stroke
f. Maximum power at rated RPM
g. BMEP at rated kw (including any parasitic loads and generator efficiency)
h. Piston speed, feet per minute
i. Make and model of governor
3. Generator Data
a. Manufacturer
b. Model
c. Rated KVA
d. Rated KW
e. Voltage
f. Temperature rise above 40 degrees C ambient
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1) Stator by thermometer ___ degrees C
2) Field by resistance ___ degrees C
3) Class of insulation ___ degrees C
4. Generator efficiency including excitation losses and at 80 percent PF
a. Full load ___ percent
b. Three-quarters load ___ percent
c. Half load ___ percent
5. Guaranteed fuel consumption rate (at generator terminals/138,000 BTU/gallon)
a. Full load, gal/hr _____
b. Three-quarters load, gal/hr _____
c. Half load, gal/hr _____
6. Generator unit and accessories
a. Weight of skid mounted unit ______lbs.
b. Overall length ______inches
c. Overall width ______inches
d. Overall height ______inches
e. Exhaust pipe size ______inches
7. Exhaust gas emissions data, maximum values at loads varying from full to 1/4 load:
a. Temperature_____ degrees F
b. Flow _____ ACFM (mass and volume)
c. Carbon Monoxide (CO) _____ grams/BHP-hr
d. Nitrogen Oxides (NOx) _____ grams/BHP-hr
e. Hydrocarbons (HC)_____ grams/BHP-hr
*Sulfur Dioxide (SO2) _____ grams/BHP-hr *Based on ___ percent sulfur content by weight in the fuel.
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8. CFM of air required for combustion and ventilation based upon inlet air temperature of 40 degrees C: ___ CFM
9. Heat radiated to room by engine and generator: ____ BTU/min
10. Heat rejected to jacket water including lubricating oil and intercooler (if required) __ BTU/min
11. Height from bottom of skid required for removing piston with connecting rod; (also for removing cylinder liner): ___-ft
12. The unit guaranteed to be adequate for motor starting as required by Paragraph 1.06C of this Specification.
13. Radiator (engine driven) fan cooling air volume and required BHP: ______BHP
C. Test Reports
1. Furnish four copies of the Manufacturers certified shop test record of the complete engine driven generator unit. The final test record shall confirm the generator set performance required in Paragraph 1.06.
1.04 REFERENCE STANDARDS
A. Design, manufacturing and assembly of elements of the equipment herein specified shall be in accordance with but not limited to published standards of the following, as applicable:
1. American Gear Manufacturers Association (AGMA)
2. American Institute of Steel Construction (AISC)
3. American Iron and Steel Institute (AISI)
4. American Society of Mechanical Engineers (ASME)
5. American National Standards Institute (ANSI)
6. American Society for Testing Materials (ASTM)
7. American Welding Society (AWS)
8. Anti-Friction Bearing Manufacturers Association (AFBMA)
9. Institute of Electrical and Electronics Engineers (IEEE)
10. Instrument Society of America (ISA)
11. International Standards Organization (ISO)
12. National Electrical Code (NEC)
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13. National Electrical Manufacturers Association (NEMA)
14. National Fire Protection Association (NFPA)
15. Occupational Safety and Health Administration (OSHA)
16. Steel Structures Painting Council (SSPC)
17. Underwriters Laboratories, Inc. (UL)
18. US Environmental Protection Agency (EPA) – New Source Performance Standard for Stationary Reciprocating Compression Ignition Engines (NSPS)
19. Florida Building Code (FBC)
B. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.
1.05 QUALITY ASSURANCE
A. The engine-generator set shall be the standard product, as modified by these specifications, of a Manufacturer regularly engaged in the production of this type of equipment and which maintains a permanent service organization and supply of spare parts in place at the time of the bid within 150 miles of the project site. The unit to be furnished shall be built from components which have proven compatibility, reliability and are coordinated to operate as a unit. The completed engine generator set shall be supplied by that Manufacturer's authorized dealer only. The dealer shall have a minimum of ten (10) years experience in the field of power generation.
B. The Genset unit with enclosure and dual-wall sub base fuel tank shall be of such physical dimensions to fit into the space provided. Maximum dimensions shall be 154” length by 52” wide by 108” high.
C. All mechanical equipment shall be designed and built for 24 hour continuous service at any and all points within the specified range of operation without overheating or excessive vibration or strain, and require only that degree of maintenance generally accepted as peculiar to the specific type of equipment required. All parts and components of all units shall be designed and built for interchangeability so that replacement parts may be installed without any additional fitting or machining.
D. Components of mechanical and electrical equipment shall be the products of Manufacturers who can produce evidence of their ability to promptly furnish any and all interchangeable replacement parts as may be needed at any time within the expected life of the equipment.
E. The contractor shall submit information on torsional forces on the engine generator and upon request, any additional information that the Engineer may deem necessary to determine the ability of the Manufacturer to produce the specified equipment.
F. The Manufacturer shall have suitable testing facilities adequate for performing the shop tests and inspections specified herein. The contractor shall submit a description of the
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Manufacturer's testing facilities. The descriptive matter shall contain illustrative photographs, drawings and such other matter as may be requested.
G. Services of Manufacturer's Representative
1. Provide services of factory-trained service technician, specifically trained on type of equipment specified. Submit qualifications of service technician for approval. Man-day requirements listed are exclusive of travel time and do not relieve contractor of obligation to provide sufficient service to place equipment in satisfactory operation.
2. Installation: to assist in location of anchor bolts; setting, leveling and field erection; coordination of piping, electrical, miscellaneous utility connections: 1 man-day.
3. Start-up, testing and calibration: 1 man-day.
4. Operation and maintenance instruction: 1 man-day.
5. Service inspections during first year of actual operation, for use at Owner's request, and exclusive of repair, malfunction, or other troubleshooting service calls: 3 man-days (not anticipated as consecutive).
1.06 UNIT PERFORMANCE
A. The automatic voltage regulation at steady state operations shall be within plus or minus 0.25 percent from zero load to full-rated load for any load variation. Upon application or removal of full-rated load in one step, the transient voltage, and recovery to steady state operation shall be within nine seconds.
B. Stable or steady state operation is defined as operation with the frequency variation not exceeding plus or minus 0.25 percent (0.15 Hertz) and voltage variation plus or minus 0.25 percent of their mean value for constant load from zero load to full rated load. A rheostat shall provide a minimum of plus or minus five percent voltage adjustment from rated voltage.
C. The generator shall be capable of accepting a block load equal to the unit’s full kW rating.
1.07 DELIVERY, STORAGE AND HANDLING
A. Ship equipment, material and spare parts complete except where partial disassembly is required by transportation regulations or for protection of components.
B. Pack spare parts in containers bearing labels clearly designating contents and pieces of equipment for which intended.
C. All mechanical and electrical equipment shall be coated, wrapped and otherwise protected from rain, drippings of any sort, dust, dirt, mud, flood and condensed water vapor during shipment and while installed in place during construction. The protective coverings shall remain in place until the work areas are substantially free of all construction dust and debris. Full details of proposed protective measures shall be submitted for approval to the Engineer prior to shipment. Generator space heater shall be energized at all times during storage.
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1.08 PROJECT/SITE REQUIREMENTS
A. The engine generator shall be installed within an outdoor enclosure. All equipment under this Section shall be designed for an ambient temperature of 43 degrees C (110 degrees F).
1.09 MAINTENANCE
A. Maintenance Service
1. Provide to the Owner, at time of acceptance of the unit(s), a written one year Manufacturer's standard service contract for the diesel engine generator and essential support systems, commencing on the date of acceptance of the unit. Contract shall include one preventive maintenance inspection of the installation prior to expiration of the warranty period to assure the safe and dependable operation of the system. The preventive maintenance inspection shall be in addition to the site visits specified in paragraph 1.05 H.5 above. This service contract does not supersede or replace the Manufacturer's standard one year equipment warranty.
2. Special Guarantee
a. Provide manufacturer’s extended guarantee or warranty, with Owner named as beneficiary, in writing, as special guarantee. Special guarantee shall provide for correction, or at the option of the Owner, removal and replacement of work specified in this Specification section found defective during a period of 2 years after the date of Substantial Completion.
B. Provide one set of all special tools that are required for the normal operation and maintenance of the engine driven generator unit.
C. Provide the following spare parts per unit:
1. Six air filter elements.
2. Six lube oil filter elements.
3. Six fuel oil filter elements.
4. One set of hoses and belts including one of each different size and type.
5. Three complete replacement sets of fuses of each different size and type.
6. One complete change of lube oil plus one gallon of make-up lube oil supplied in unopened containers.
7. One complete change of ethylene glycol anti-freeze solution to provide a 50 percent solution in the engine cooling system supplied in unopened containers.
D. The spare parts and maintenance tools shall be packed in containers, permanently labeled by word and part number for easy identification of the items and with the words "For Use Only for the Diesel Engine Generator Unit" and properly packed for an extended period of storage before use.
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PART 2 PRODUCTS
2.01 GENERAL
A. The engine-generator sets shall be a factory assembled unit, properly housed as later specified and for outdoor operation and specifically designed and equipped for operation on No.2 diesel fuel oil, and shall be Caterpillar XXX (EPA Tier 3) or equal by Cummins or Kohler. The engine and generator shall be directly connected with a semi-flexible steel coupling, shall be free from injurious torsional or other vibration and shall be vibro-mounted with a heavy steel sub-base. The diesel engine shall be vertical in-line, or V-type not over sixteen cylinders, four stroke cycle, turbo-charged with intercooler using engine jacket water, full diesel, mechanical injection, arranged for direct connection to an alternating current generator. The unit shall operate at a rotative speed of not more than 1800 rpm. Units offered at ratings in excess of their published ratings are not acceptable and will not be approved.
B. The engines shall be rigid, neat in appearance and shall allow easy access to the various parts for maintenance purposes. The bed plate and frame shall be of heavy construction. All parts shall be properly enclosed to prevent the throwing or dripping of oil.
C. The engine-generator sets shall be pre-piped and pre-wired insofar as possible. Separate pre-wired terminal boxes shall be provided on the engine-generator skid for A.C. and D.C. wiring.
2.02 ENGINES
A. General
1. The engines shall be capable of withstanding a 10 percent overload for two hours out of every 24 hours without harmful detonation, overheating or other evidence of distress.
2. The complete engine-generator unit shall be free from harmful torsional or other vibration throughout the entire operation range of speed and load.
2.03 EQUIPMENT
A. Governors
1. The engine governor shall be an electronic isochronous speed controller. Speed droop shall be externally adjustable from 0 to 10% from no load to full rated load and shall automatically adjust generator frequency from within a maximum of 0.25% of rated frequency under steady state operating no load and loaded conditions. Speed shall be sensed by a magnetic pickup off the engine flywheel ring gear. A provision for remote speed adjustment shall be included. The governor shall incorporate provisions for limiting fuel during start-up, and included capability for compensation adjustment. The use of generator set manufacturer’s factory installed electronic engine control system to perform the governor functions of controlling fuel and speed is acceptable.
2. Furnish also a separate overspeed shutdown device which shall, in case of predetermined overspeed or the operation of various protective devices as later specified, instantly stop the engine without the fuel injection system loosing its prime.
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B. Supporting Structure
1. The diesel engine-generator shall be directly bolted, doweled, and aligned on a rigid, fabricated steel base, suitably sized to maintain the correct alignment, supported by Korfund or equal heavy duty spring type vibro isolators, anchored to the level surface of a concrete pad.
2.04 FUEL SYSTEMS
A. Base Tank - The unit shall be equipped with a double wall in-base fuel tank. Minimum usablecapacity shall be 250 U.S. gallons and the tank shall be supplied with a lockable, interior-located fill cap. All necessary fuel and vent lines for proper engine performance will be provided as well as a means to readily detect the fuel level in the tank without the use of a measuring stick. The fuel level system shall provide two 4-20 mAmp outputs for remote monitoring. A base tank electronic leak detection system shall be provided, and an two sets of alarm contacts shall be provided for annunciation at the automatic transfer switch and remote monitoring. The in-base fuel tank shall be of such physical dimensions to fit into the space provided as indicated on the Drawings.
B. The fuel tank base shall be formed from steel of a minimum metal thickness of 0.25 inch (1/4 inch) and shall be fitted with low and high fuel level alarm contacts for annunciation at the automatic transfer switch. The tank shall be constructed of corrosion resistant steel and shall be UL listed.
C. An engine driven fuel pump, taking its suction from the base tank shall deliver the fuel oil to the engine injection system through a duplex oil filter of the replaceable element type. The excess fuel supplied to the engine shall be returned to the base tank.
D. All parts of the fuel system shall meet the approval of, and be installed in complete compliance with, all applicable local, state and federal codes, laws and regulations. The base tank shall have the same maximum length and depth as that of the Genset equipment.
E. Electric (Battery) Starting Systems
1. Starting shall be accomplished by an engine mounted, solenoid shift electric starter, capable of withstanding four consecutive continuous cranking periods of 15 seconds duration each separated by 15 seconds rest periods before shutting down completely and sounding the alarm.
2. The starting battery(ies) shall be low maintenance, long life, lead calcium type, especially designed for diesel engine cranking service, and of a capacity as recommended by the battery Manufacturer for cranking the engine being furnished, for the necessary break-away current as required and the spinning current for four consecutive starts of 15 seconds of cranking on each start, without being recharged, with a battery temperature of 45 degrees F and with the SAE 30 oil in the engine maintained at 60 degrees F. The battery(ies) shall be manufactured by CTD Power Systems, Chloride, or equal. An insulated protective covering, battery rack and suitable cables shall be provided.
3. Cell containers shall be sealed, translucent, shock absorbing, heat resistant plastic with electrolyte level marks and spray proof, flame arresting type vents. Battery shall be
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furnished with all connectors and hardware, lifting device, electrolyte terminal plates, cables, grease, hydrometer and brushes for cleaning posts and connectors.
4. Floor mounted structural steel battery racks shall be furnished specifically designed for battery service. The racks shall be finished with an acid and fire resistant epoxy coating and non-metallic rain covers.
5. Battery chargers shall be a UL listed, fully automatic, filtered, float-type, charger suitable for wall or rack mounting. Input voltage shall be 120 volts A.C., single phase, 60 Hz. The D.C. output shall be regulated to within one percent with plus or minus ten percent fluctuations of the input voltage and shall be current limited at 120 percent of rated output. Accessories shall include D.C. ammeter and voltmeter (panel type; 2 percent accuracy), adjustable float and equalize controls and toggle switch, A.C. and D.C. circuit breakers, A.C. power failure alarm relay, low D.C. voltage alarm relay and D.C. ground fault relay. The charger shall be Chloride Model SCR-F; LaMarche Model A12B or equal.
F. Air Intake Systems
1. The engines shall be equipped with suitably sized dry type air intake filter(s) to protect working parts of the engine from dirt and grit with replaceable type filter element. In-line air inlet silencers shall be provided between the turbocharger and the air inlet filter. A crankcase breather shall be included.
G. Lubrication System
1. The engines shall be provided with a full pressure lubricating oil system arranged to cool the pistons and to distribute oil to all moving parts of the engine including the turbocharger bearings and including full flow filter of the replaceable element type and a suitably sized shell and tube type oil cooler and an AMOT or equal automatic temperature regulator. An engine driven lubricating oil circulating pump shall be provided for the engine. This pump shall be of the positive displacement type, and shall have ample capacity to circulate the amount of lubricating oil and cooling oil required by the engine and turbocharger. The engines shall be provided with a sump type crankcase arrangement of sufficient capacity to suit the requirements of the engine.
H. Engine Cooling Systems
1. The units shall be radiator cooled with a blower or pusher type fan mechanically driven by the engine. Fan and belts shall be completely guarded in accordance with OSHA regulations. The cooling system shall be adequate for cooling the units at full rated load and, for installation in a climate where freezing temperatures are encountered, shall be adequate for proper cooling in summer with a 50 percent ethylene glycol anti-freeze solution in the radiator, and with an ambient temperature of 100 degrees F. A pressurized radiator cap, if used, shall be rated for not more than 6 PSI on the cooling systems. Furnish and install a suitable air discharge duct from the face of the radiator to the wall and incorporate in the wall automatic discharge dampers which shall automatically open when the unit starts and automatically close when the unit stops. The automatic dampers shall be furnished and installed as specified herein. The cooling system shall be adequate for properly cooling the unit at full rated KW capacity and with an ambient temperature of 120 degrees F. Louvers or openings shall be properly screened to prevent the entry of
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rodents, insects or birds.
a. Attached engine driven, centrifugal jacket water pump equipped with a mechanical seal and capable of circulating the required amount of jacket water through the radiator and required additional piping, to be suitably sized and furnished by engine manufacturer.
b. A suitably sized full flow lubricating oil cooler.
c. Provide AMOT or equal automatic temperature regulators for the engine jacket water and lubricating oil which shall maintain pre-set temperature without restricting the rates of flow through the engine.
d. The engine thermostat shall be "AMOT" or equal which shall automatically maintain jacket water temperature at predetermined values without restricting the rate of flow through the engine.
e. The temperature regulators, and other cooling system components shall, as far as practical, be mounted on the engine or unit sub-base and factory piped. All external connections to the engine shall be made with flexible metal hose suitable for the pressure and temperatures involved. All pipe sizes shall be as recommended by the engine manufacturer.
f. As required by the manufacturer, the expansion tank shall be roof mounted adjacent to the silencer. Manufacturer shall provide all piping, supports, building modifications, etc. as required for a complete installation.
2. Provide suitable jacket water treatment for the prevention of both scale formation and corrosion in the engine water jackets and cooling system components which are in contact with the engine jacket water. This treatment shall be added to the cooling system prior to running the field acceptance test. The treatment shall be NALCOOL 2000 as supplied by and applied in strict accordance with the recommendations of the NALCO Chemical Company, 6233 West 65th Street, Chicago, IL 60638, or equal.
Before adding the recommended treatment, the engine jacket water system shall be thoroughly cleaned and conditioned, using NALCO 2015 Twin Pac, two step engine cooling system cleaning treatment, or equal, strictly in accordance with the manufacturer's instructions and using particular care to thoroughly flush and remove the soda ash immediately after 15 minutes of idling engine operation
I. Exhaust System
1. High degree exhaust silencer, G.T. Exhaust Systems, Inc. Model 201-6100 Series, or equal, for super critical hospital grade silencing, shall be installed. The exhaust silencer noise attenuation shall be 32 to 40 dBA and be aluminized steel construction. The exhaust piping shall be Type 302 with wall thickness of 0.250-in, stainless steel with flanged fittings and of the size recommended by the engine Manufacturer. Suitable stainless steel bellows expansion joints shall be provided and installed where required to provide for expansion of the pipe caused by a 1200 degree F temperature change. The exhaust line shall be connected to the engine by a suitable section of flexible stainless steel metal exhaust hose as recommended by the engine Manufacturer as suitable for the
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maximum temperature condition which may be encountered. All exhaust line elbows shall be long radius. Provision for installation of smoke density monitoring equipment shall be made as indicated on the Drawings.
2. Furnish and install suitable equipment for the engine exhaust to attenuate the sum of the octave bank levels converted to A-weighted sound pressure levels to not be in excess of 75 dBA at a distance of 50 feet in any direction from the point of discharge to the atmosphere.
3. For the exhaust there shall be included the attenuation curve for the silencing equipment as offered to accomplish the required results of this installation.
4. Octave band sound pressure level readings shall be taken and recorded at the time of the onsite field test and to be acceptable must be within the limits permitted by this Specification.
5. If changes are necessary to accomplish the required exhaust silencing, the contractor shall furnish a revised exhaust arrangement drawing which must be approved by the Engineer.
6. The entire exhaust systems shall be installed in the field, except the flexible section, but including the exhaust silencer and shall be covered with insulation of a non-combustible type and jacketed with an aluminum jacket. The insulation for the silencer shall be 4-in thick, Fibrex Industrial Flexible Batt Insulation IF1260, or equal, and for the piping shall be Coreplus 1200, or equal, held in place with stainless steel banding and covered with a 0.016 or 0.020-in aluminum jacket, secured with screws and jacketing lapped a minimum of 3-in. The aluminum jacket shall be separately applied at the job site. Fittings and flanges shall be insulated with MF pipe covering material cut to fit. No asbestos or asbestos bearing products be used. Flexible sections of the exhaust systems shall be protected by a suitable metal guard to prevent personal injury from a burn if in contact with bare flesh. Include all required steel support framing and hanger bands for mounting of the silencer to the overhead concrete structure and all support saddles for roof mounting.
7. Furnish and install complete exhaust systems, including silencer, flanged piping with a single (sleeve) thimble through wall designed to accommodate the required 4-in thick insulation and the complete supporting system. The exhaust pipe shall be directed vertically by means of long radius elbow, terminating with a 316 stainless steel counterbalance raincap with bronze bushings equal to Rain Fighter Systems Inc., Shreveport, LA.
8. A suitable drain with valve shall be installed at the low point of the exhaust line. The thimble sleeves shall be sealed with an approved compound. The entire installation shall meet with the Engineer's approval.
9. It is the intent of this specification to provide complete compliance with all applicable local, State and Federal codes, laws and regulations.
J. Miscellaneous Equipment and Requirements
1. Heaters
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a. Automatic thermostatically controlled heaters, rated 1.5 KW 120 volt, single phase, shall be provided to maintain not less than 90 degrees F temperature with an ambient temperature of 40 degrees F (4.5 degrees C) for the engine jacket water and engine lubricating oil system(s).
b. All heaters shall be automatically deactivated when the engine generator unit is in operation.
2. Field Piping
a. All required field piping except for engine fuel, exhaust and air starting piping shall be seamless copper, Type L and sizes as recommended by the engine Manufacturer and shall have approved fittings with soldered joints. Flanges or unions shall be provided as required to make disassembly for repairs easy. All connections to the engine shall be made with flexible metal hose of an approved type. Fuel, exhaust and air starting piping shall be as specified earlier in this Section.
3. Hearing Protection
a. Two circumaural hearing protection devices MSA Noisefoe Mark IV ear muffs or equal shall be furnished for the protection of operating personnel. Provide with high impact plastic window type cabinet, suitable for wall mounting.
4. Flexible all-metal connectors for all field-piped connections to the engine.
2.05 ENGINE INSTRUMENTATION AND CONTROLS
A. Generator Control Panels
B. An engine mounted 14 gauge steel control panel shall be furnished and mounted on the generator skid unit. The panel shall contain, but not be limited to, the following equipment:
1. Frequency Meter, 3 1/2-inch, dial type.
2. Voltmeter, 3 1/2-inch, 2 percent accuracy.
3. Ammeter, 3 1/2-inch, 2 percent accuracy.
4. Ammeter phase selector switch.
5. Voltmeter selector switch (4 position) line-to-line.
6. Automatic starting controls as specified.
7. Voltage level adjustment rheostat.
8. Dry contacts for remote alarms wired to terminal strips.
9. Main line circuit breaker.
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10. Individual fault indicator lights for low oil pressure, high water temperature, overspeed, and overcrank with pre alarm and remote alarm contacts.
11. Four position function switch marked "auto," "manual," "off/reset," and "stop."
12. Running time meter, oil pressure and water temperature gauges.
13. Panel lights, transformers, fuses, etc., as required.
14. Panel mounted kilowatt meter.
15. Provide transducers on the voltmeter and kw meter with 4-20 ma transmitters for telemetry use.
16. Unit mounted annunciator with audio/visual alarms and individual fault indicator lights. Provide additional dry contact alarm for each condition.
17. Emergency stop pushbutton.
18. Provide dry contacts for remote emergency stop push button.
19. Provide dry contacts for generator in auto, generator fault, generator running, fuel leak alarm, and remote start/stop.
20. Provide 4-20 mA outputs for fuel tank level.
C. The main-line, molded case circuit breaker shall be installed on the generator unit and sized to the output of the generator. The location of the breaker (left or right hand will be confirmed during the shop drawing review process). The trip unit for each pole shall have elements providing inverse time delay during overload conditions and instantaneous magnetic tripping for short circuit protection.
2.06 GENERATORS AND EXCITATION SYSTEMS
A. The generator shall be of the drip-proof, guarded, bracket type, especially designed for connection to the specified engine and shall be for 3-phase, 60-Hertz, 4-wire, 480-volt operation and shall be "Y" connected. The generator shall be mechanically and torsionally matched to the engine driver and shall be designed to withstand inherent pulsating torques of the engine.
B. The generator shall be as manufactured by Caterpillar, Kato; Louis Allis, Inc.; Marathon Electric or equal; shall have a forged or cast alloy steel flanged shaft for direct connection through a suitable flywheel type coupling to the engine, or with suitable adapter and disc coupling; and shall be of the single bearing type with anti-friction bearing. Full load efficiency of the combined generator, exciter and regulator shall be not less than 93 percent.
C. The generator windings, insulation and excitation system shall be braced to withstand any possible short-circuit stresses and shall be designed to withstand any overheating or stresses caused by harmonics generated by the variable frequency drives. The excitation and voltage control system shall sustain at least 300 percent rated generated current for ten seconds when a 3 phase symmetrical short-circuit is applied at the generator terminals. The unit shall be
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"Radio Interference Proof" (RIP) and the "Telephone Influence Factor" (TIF) shall be within the limits of Section 9, ANSI C50.12.
D. The generator shall utilize a brushless, rotating field, Permanent Magnetic Generator (PMG) type excitation system with an electronic closed loop voltage regulator. The exciter rotor and field windings shall have Class F insulation, rated for Class B temperature rise.
E. The generator armature and field windings shall have Class F vacuum/pressure impregnated (VPI) epoxy insulation, limited to Class B (80 degrees C) temperature rise.
F. The generator stator core shall be built up of low carbon steel laminating precision punched, deburred and individually insulated. Stator coils shall be all copper, random or form wound and inserted in insulated core slots. Wound core shall be repeatedly treated a minimum of three times with thermosetting synthetic varnish and backed for maximum moisture resistance, high dielectric strength and high bonding qualities. Armature lamination followers and frame ribs shall be welded integral with frame.
G. The generator shall be furnished with 120 volt anti-condensation space heaters, designed to hold a minimum temperature of 90 degrees F.
H. Generator rotor poles shall be built up of individually insulated steel punchings. Poles shall be wound and bonded with high strength varnish, then baked. Cage connections shall be brazed for strong construction and permanent electrical characteristics. Each pole shall be dovetailed and keyed to rotor shaft. The rotor shall be dynamically balanced for all speeds up to 125 percent of rated speed per NEMA specifications.
1. The entire rotor assembly shall be 100 percent epoxy resin vacuum pressure impregnated, then baked.
I. A cooling fan shall be mounted on the rotor to draw air from exciter end, over rotor poles and through louvered openings in drive end.
J. The generator shall have an oil lubricated anti-friction bearing. The designed bearing life, based on B-10 curve of the Anti-Friction Bearing Manufacturers' Association, shall not be less than 40,000 hours.
K. Voltage regulator shall be hermetically sealed, silicon controlled rectifier type and shall employ a zener reference and three phase sensing. The voltage regulator shall provide automatic protection of the entire unit on 3 phase short-circuits. The voltage regulator shall include automatic overexcitation and underfrequency protection. Input isolation transformers and filters shall be provided to minimize disturbances caused by line harmonics. Exciter shall be fast response type with a rotating rectifier and surge suppresser, 3 phase, full-wave bridge. It shall feature low time constant design to minimize voltage transients under severe load changes.
L. Voltage regulation shall be within plus or minus 1 percent of rated voltage from no load to full load. Steady-state modulation shall not exceed plus or minus 1/2 percent. Instantaneous voltage dip shall not exceed 20 percent of rated voltage when full load at rated power factor is applied. Recovery of stable operation shall occur within one second.
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M. The voltage regulator and associated equipment shall be mounted in the generator terminal box.
N. Generator stator leads shall be connected to copper bus bars in an oversize terminal box with differential and ground fault protection current transformers.
2.07 SURFACE PREPARATION AND SHOP PAINTING
A. The engine generator set and associated equipment shall be shop primed and finished coated in accordance with the Manufacturer's standard practice prior to shipment. Color shall be selected by the Engineer and an adequate supply of touch-up paint shall be supplied by the Manufacturer.
2.08 SHOP TEST
A. A complete engine generator unit and the generator main breaker and control panels shall be shop tested prior to shipment. Four copies of the complete certified test record shall be submitted to the Engineer within 30 days after the completed test.
B. These tests for the unit shall be sufficient to assure that the unit will operate successfully and meet all specified operational requirements. The Manufacturer shall furnish all necessary instruments, filters, starting air, fuel gas, cooling water, electric power and load banks for the test.
C. The shop test shall consist of, but not be limited to, four continuous hours of operation. Voltage and frequency regulation and transient response shall be tested and recorded to show full compliance with this specification. During the shop test, readings shall be taken and recorded every thirty minutes for each of the following:
1. Time
2. Ambient temperature
3. Volts for each phase
4. Load:
a. Amps for each phase
b. KW
c. Power factor
d. Frequency
e. Engine jacket water temperature
f. Cooling water temperature (in and out)
g. Intake manifold pressure
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h. Lubricating oil pressure
i. Crankcase pressure
j. Lube oil temperature
k. Intake manifold temperature
l. Exhaust gas temperature
m. Raw water cooling flow for heat exchanger
n. Gallons of fuel consumed per hour
D. The generator shall be shop tested in accordance with IEEE Standard 115. Testing shall include the following:
1. Cold resistance of all windings
2. Insulation resistance of all windings
3. Polarity of field coils
4. High potential on all windings
5. Open circuit saturation
6. Air gap measurement
7. Regulation (with regulator)
8. Transient voltage dip and response
9. Voltage and current balance
E. The procedure for the shop test of the diesel engine shall cover the engine Manufacturer's standard practice and shall also include at least, but not be limited, to the following:
1. Prior to all starts during initial tests and all starts after new running parts have been installed, the engine shall be connected to a separately driven lubricating oil pump and filtered oil circulated through all of the engine channels. The engine shall be thoroughly inspected for oil leaks prior to shipment, paying particular attention to leaks around the shims of bearing shells in engines where shims are used.
2. The engine shall be prelubricated for a sufficient period of time to insure adequate lubrication. Caution shall be taken to avoid the accumulation of oil in the combustion chambers.
3. Engine and generator alignment shall be checked and generator air gap measured prior to the test.
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F. Provision shall be made for bypass filtering and full-flow straining of the lubricating oil during the test. The strainer shall be so constructed that it will not pass particles over 0.003-in.
1. The engine shall be tested with the governor intended for permanent use on the engine. New, clean lubricating oil shall be used in the governor.
2. An air filter or cleaner shall be used for the supply of combustion air during all testing.
3. All starting air lines shall be fitted with water traps and lubricators.
4. The engine shall be given a suitable wearing-in run before the witnessed shop test as recommended by the Manufacturer. Before recording any readings, all operating temperatures and pressures shall have become stabilized.
5. All alarm, shutdown, and control functions shall be demonstrated. Transient response shall be measured to indicate compliance with the performance specifications.
G. After completion of all testing, the following is required:
1. The load limit shall be sealed. The seal shall be applied, using a seal press which embosses the Manufacturer's initials on the lead seal.
2. All entrapped water shall be drained, and proper protection applied to prevent the entry of water during shipment or a long period in storage while waiting for installation.
3. The engine shall be given proper treatment for its protection for extended storage at the job site while waiting for completion of installation.
H. Manufacturer shall include in their bid all costs (including but not limited to transportation, lodging, meals, expenses, etc.) for two (2) Owner designated representatives to witness the shop testing. All costs shall be sufficient to include proper allotment of days/nights necessary for successful completion and passing of the shop tests.
2.09 MODULAR SOUND ATTENUATED WEATHERPROOF ENCLOSURES
A. The complete engine-generator set, main line circuit breaker, critical grade silencer with a rain cap, battery charger, day tank, etc. shall be enclosed within a modular sound-attenuated weatherproof enclosure. The enclosure shall be constructed of removable side panels and end panels and shall be slip-over mounted on the skid. All air inlets shall be louvered to aid in noise reduction. The enclosure shall limit the sound levels to 79 dBA at 23 feet.
B. The top, end and side panels shall be made from 12-gauge galvanized steel construction. The design of the enclosure shall prevent rodents from entering the unit. The units shall have hinged side doors on each side and double hinged doors to allow access to the engine, alternator, and control panel for servicing and maintenance. To prevent tampering, the enclosures shall have key-lockable doors. The roof overhangs shall have drip ledges which direct rain off the enclosure. All hardware and hinges shall be 316 Series stainless steel. There shall be expanded metal grating in front for the radiator grill and fixed louvered air intake ports on the shelter sides and rear for proper air circulation within the shelter. The complete generator set and shelter shall be prime-painted and have two finish coats of protective enamel paint. Paint color shall be as selected by the Engineer. Provisions shall be available for crane
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unloading by providing lifting eyes and spreader bar reinforcement.
C. The enclosure shall be designed and braced to resist 150-MPH winds, and shall include a minimum of two (2) 75 watt 120 volt lighting fixtures and switches on both sides of the enclosure access doors completely wired ready for field power connection. The lights will be powered from the local lighting panel as shown on the Drawings.
D. All louvers shall be furnished with 0.125-inch mesh, 0.028-inch diameter 304 stainless steel wire insect screen secured within a heavy-duty two-piece extruded aluminum frame. Screening shall be field-replaceable within extruded frame. The frame shall be mounted on the inside face of the louver and shall be attached by means of self-tapping stainless steel wing screws.
PART 3 EXECUTION
3.01 COORDINATION
A. Coordinate with other trades, equipment, and systems to the fullest extent possible.
3.02 INSTALLATION
A. Provide services of a qualified field representative with a minimum of 5 years experience in diesel engine generator set installations, training and instruction to check the installation of the generator unit to ensure a proper installation.
B. The complete generator unit shall be mounted on a welded steel subbase of sufficient rigidity and strength to maintain alignment of the unit. The base shall be suitable for, and there shall be included, spring type vibro-isolators for mounting the unit on a level surface of a concrete pad. The spring type vibro-isolators shall be supplied by the generator unit Manufacturer.
3.03 EQUIPMENT START-UP
A. Operate unit to demonstrate ability to operate continuously without vibration, jamming, leakage or overheating and to perform specified functions, after installation and after Manufacturer's representative check of installed equipment.
B. Comply with Manufacturer's operating and maintenance instructions during start-up and operation.
C. Promptly correct improper installation of equipment.
D. Cooperate with supplier of equipment at time of start-up and in making of all final adjustments necessary to place equipment in satisfactory working order. Start-up shall not commence without the presence of the Manufacturer's representative.
3.04 FIELD TEST
A. Upon completion of the installation and as soon as conditions permit, the emergency power supply system including the engine driven generator, electrical circuits, controls, transfer switch and other devices shall be tested in the presence of the Engineer by the contractor and
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the service representative for the Manufacturer of the engine driven generator unit to assure that the system functions as specified.
1. Prior to scheduling the test, the contractor shall notify the Engineer in writing that all requirements and provisions of the Contract Documents have been fulfilled, that all apparatus shall be clean, properly adjusted and ready for operation and that the Instruction Manuals, parts lists and record drawings described in Paragraph 1.03, have been submitted.
2. The Manufacturers' representatives shall make such changes in wiring or connections and such adjustments, repairs or replacements necessary to make the circuit, device or control system function as specified and otherwise comply with the Contract Documents.
B. The test shall consist of four hours of continuous operation of the unit at full rated load using a portable resistive load bank. During the test, the same readings as outlined under Shop Test Paragraph 2.08C, shall be taken and recorded at 30 minute intervals.
C. As part of the field test, each of the automatic shutdown devices shall be tested and the respective values recorded at which the devices will stop the engine. Any adjustments required shall be made in the devices to make the operating values correspond to those recommended by the engine Manufacturer and as recorded during the stop test.
D. After the four hour test has been completed, additional testing shall be performed to demonstrate the emergency power supply system's ability to meet the automatic starting, load transfer and motor starting requirements as specified under Paragraph 1.01C and 1.06C.
E. The contractor shall provide a person qualified to conduct sound level testing to take and record octave band sound pressure level readings with the portable resistive load shut off and operating the engine driven generator using the station load available at the time the field tests are conducted. These readings shall be within the limits permitted by this specification.
F. Piping shall be tested in strict accordance with the Manufacturers testing requirements. For each double wall fuel oil line entering the building, provide a pressure test port with threaded plug in the double wall piping termination fitting. Piping shall be subjected to an air test of 10 psig maximum.
G. If the emergency power supply system fails to fulfill the performance requirements of this specification, corrective action shall be taken and the system retested to assure full compliance. All expenses associated with the field tests, including any corrective action, shall be borne to the contractor.
END OF SECTION
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SECTION 16370
VARIABLE FREQUENCY DRIVES
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required to manufacture, assemble, shop-test, and install variable frequency drives with integral isolation/phase shift transformers, as shown on the Drawings and as specified herein. All variable frequency drives shall be furnished by the equipment manufacturer as specified in Division 11.
B. These specifications are intended to give a general description of what is required, but do not cover all details that will vary in accordance with the requirements of the equipment furnished. They are, however, intended to cover the furnishing, the shop testing, the delivery and complete installation and field testing, of all materials, equipment and appurtenances for the variable frequency drives herein specified.
C. The Contractor shall furnish only one manufacturer of variable frequency drives as specified herein.
D. The work shall include the services of factory representatives of the variable frequency drive manufacturers to inspect the final installation, to perform field acceptance tests on the installed equipment and to instruct the regular operating personnel in the care, operation and maintenance of equipment.
1.02 RELATED WORK
A. Concrete for equipment pad is specified in Division 3.
B. Pumps are specified in Division 11.
C. Motors are specified in Section 16150.
1.03 SUBMITTALS
A. Copies of all materials required to establish compliance with the specifications shall be submitted. Submittals shall include at least the following:
1. Copy of this specification confirming compliance with each paragraph.
2. Certified shop and erection drawings showing all important details of construction, dimensions and anchor bolt locations. Details to also include front elevations with designation of devices and equipment on door(s) and internal to the enclosure. Internal layout of components including dimensions and space requirements. Standard preprinted sheets or drawings simply marked to indicate applicability to this contract will not be acceptable.
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3. Descriptive literature, bulletins and/or catalogs of the equipment.
4. Data on the characteristics and performance of the variable frequency drives. Data shall include certification that the variable frequency drives are warranted for use with the motors specified in Division 11 and Section 16150. Data shall include:
a. Efficiencies and power factor
b. Continuous and fault ratings of drive and disconnecting means.
c. Maximum heat dissipation from enclosure.
5. Complete drawings shall be furnished for approval before proceeding with manufacture and shall consist of job specific master wiring diagrams, elementary or control schematics including coordination with other electrical control devices operating in conjunction with the variable frequency drive, and suitable outline drawings with sufficient details for locating conduit stub-ups and field wiring. Due to the complexity of the system, it is imperative the above drawings be clear and carefully prepared to facilitate interconnections with other equipment. Standard preprinted sheets or drawings simply marked to indicate applicability to this contract will not be acceptable.
6. The total weight of the equipment including the weight of the single largest item.
7. A complete total bill of materials of all equipment.
8. Harmonic analysis.
9. A list of the manufacturer's recommended spare parts with the manufacturer’s current price for each item.
10. Field test and inspection reports.
11. Operation and maintenance manuals.
1.04 SYSTEM DESCRIPTION
A. The variable frequency drives specified hereinafter will be furnished as a complete system as specified in Division 11. The Contractor shall coordinate with the manufacturer of the Division 11 equipment to ensure the installation compatibility of the equipment.
B. The variable frequency drives will operate motors as specified in Division 11 and Section 16150. The drives furnished herein under shall be totally compatible with the Motors to be supplied.
C. Additional controls shall be provided as required by Division 11 and 13 and as shown on the drawings.
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1.05 DELIVERY, STORAGE AND HANDLING
A. All parts shall be properly protected so that no damage or deterioration will occur during a prolonged delay from the time of shipment until installation is completed and the units and equipment are ready for operation.
B. All equipment and spare parts must be properly protected against any damage during a prolonged period at the site.
C. Factory assembled parts and components shall not be dismantled for shipment unless permission is received in writing from the Engineer.
D. Each box or package shall be properly marked to show its net weight in addition to its contents.
E. Electrical equipment shall at all times during manufacture, testing, delivery and construction be adequately protected against mechanical injury or damage by water. Electrical equipment shall not be stored out-of-doors. Electrical equipment shall be stored in dry permanent shelters. Temporary connections shall be provided to operate space heaters and temporary lights required for heat shall be provided to control moisture. If any apparatus has been damaged prior to acceptance the Owner, such damage shall be repaired by the Contractor at his own cost and expense. If any apparatus has been subject to possible injury by water, it shall be thoroughly dried out and put through such special tests as directed by the Engineer, at the cost and expense of the Contractor, or shall be replaced by the Contractor at his own expense.
1.06 TOOLS AND SPARE PARTS
A. One (1) set of all special tools required for normal operation and maintenance shall be provided.
B. The manufacturer shall furnish a complete list of recommended spare parts necessary for the first five (5) years of operation.
C. The following spare parts shall be furnished for each VFD:
1. Three (3) of each type power and control fuse.
2. Six (6) of each type lamp.
3. Two (2) spare lamp lenses of each color and type.
4. Boards
5. Cooling fans
D. Spare parts shall be boxed or packaged for long term storage and clearly identified on the exterior of the package. Identify each item with manufacturers name, description and part number.
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1.07 QUALIFICATIONS / MANUFACTURERS
A. Variable speed drives shall be of sufficient size for the duty to be performed and shall not exceed their full-rated capacity when the driven equipment is operating as specified.
B. The manufacturer of this equipment shall have produced similar electrical equipment for a minimum period of five (5) years. When requested by the Engineer, an acceptable list of installations with similar equipment shall be provided demonstrating compliance with this requirement. The equipment furnished shall be designed, constructed and installed in accordance with the best practice and methods, and shall operate satisfactorily when installed.
C. All equipment furnished under these Specifications shall be new and unused and shall be the standard cataloged product of a manufacturer having a successful record of manufacturing and servicing the equipment and systems specified herein for a minimum of five (5) years.
D. The variable frequency drive manufacturer shall maintain, as part of a national network (United States), engineering service facilities within 250 miles of the project site to provide start-up service, emergency service, calls, repair work, service contracts, and maintenance and training of customer personnel. When requested by the Engineer, documentation shall be provided showing compliance, capabilities and references for this requirement.
E. The manufacturer of the assembly shall be the manufacturer of the major components within the assembly.
F. For the equipment specified herein, the manufacturer shall be ISO 9000, 9001 or 9002 certified.
G. Approved manufacturers: Allen-Bradley PowerFlex 700.
1.08 OPERATING INSTRUCTIONS
A. The operating and maintenance manuals shall be furnished in accordance with Section 01730. The manuals shall be prepared specifically for this installation and shall include all required cuts, drawings, equipment lists, descriptions, etc. that are required to instruct operating and maintenance personnel unfamiliar with such equipment.
B. A factory trained representative of the manufacturer who has complete knowledge of proper operation and maintenance of the specified equipment shall provide all the instruction and training as specified herein. This shall be done in conjunction with and coordinated with the O&M instructions to be provided for the equipment, motors and control panels.
C. The cost of training programs to be conducted with Owner's personnel shall be included in the Contract Price. The training and instruction, insofar as practicable, shall be directly related to the System being supplied.
D. The manufacturer shall provide classroom training detailed manuals to supplement the training courses. The manuals shall include specific details of equipment supplied and operations specific to the project as per Section 01730.
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E. The manufacturer shall make use of teaching aids, manuals, slide/video presentations, etc. After the training services, such materials shall be delivered to Owner.
F. The training program shall represent a comprehensive program covering all aspects of the VFD and maintenance of the system.
G. All training schedules shall be coordinated with and at the convenience of the Owner. Shift training may be required to correspond to the Owner's working schedule.
H. On-site Training: On-site (field) training shall be conducted at the Owner's site and shall provide detailed hands-on instruction to Owner's personnel covering: system debugging, program modification, trouble-shooting, maintenance procedures, calibration procedures, and system operation. The training shall run at times chosen by the Owner. The training shall be conducted for the time period as specified in Section 16000.
I. The Owner may videotape the training for future training by the Owner.
1.09 WARRANTY
A. All equipment supplied under this Section shall be warranted by the Contractor and the equipment manufacturers for a period of one (1) year Owner acceptance in accordance with Section 01740.
B. The equipment shall be warranted to be free from defects in workmanship, design and materials. If any part of the equipment should fail during the warranty period, it shall be replaced and the machine(s) and the unit(s) restored to service at no additional cost to the Owner.
C. The manufacturer's warranty period shall run concurrently with the Contractor's warranty period. No exception to this provision shall be allowed.
1.10 HARMONICS STUDY
A. Provide an electrical system harmonics study for the electrical distribution system including utility and generator sources. The goal of the study shall be to determine requirements for the variable frequency drives as required to comply with the harmonic distortion levels.
B. The harmonics study shall verify compliance with the harmonics and line notching requirements specified herein, with information on the filter system (if necessary) required to achieve the specified levels. The study shall be based on and contain, as a minimum, the following:
1. Minimum utility system short circuit kVA (confirm in writing with utility); with all VFDs operating simultaneously, operating over a 60 to 100 percent speed range. The location point of common coupling shall be the secondary of the utility transformers.
2. Explanation of method used to perform the study.
3. Explanation of study results with specific recommendations on filters and/or other measures that will be implemented to meet the specified limits.
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4. All calculations and/or computer printouts used to arrive at the recommendations.
5. Individual drive voltage and current harmonic content up to the fiftieth harmonic, and the combined total of all the drive harmonic contents reflected in the system source supply voltage and current as a percent of the 60 hz fundamental under actual load conditions from 0 - 60 hz at 10 Hz increments.
C. The harmonic distortion on the total installed distribution system for voltage and current distortion levels and line notching shall meet the requirements of IEEE 519-1992. Capacitor-Inductor filter traps that require tuning to the power system are not acceptable. The Variable frequency drive manufacturer shall provide for the design, furnishing and installation of the filtering and appurtenances required to meet the requirements as specified herein. Any costs associated with provision of and installation, space, wiring, conduit, etc. for filtering equipment shall be provided at no additional cost to the Owner.
D. The manufacturer shall be responsible to provide all data necessary to perform the study. This includes feeder cable sizes, approximate feeder length motor data, switchgear data, utility data, generator data, existing field data (if required) and any other information relevant to the study.
E. The report shall be provided prior to or with the variable frequency drive shop drawings for approval. Submittals for the variable frequency drives submitted prior to or without the study will be considered incomplete and returned to the Contractor unreviewed.
F. The variable frequency drive manufacturer is responsible to provide an up-to-date single line diagram with referenced data within the submittal for this study.
G. The study shall also address methods the manufacturer is providing to address the problems associated with “dv/dt” and “reflected waves” based on the installation (wiring, conduit, lengths, etc.) as required by the contract documents. The equipment to address any problems shall be included and provided at no additional cost to the Owner.
PART 2 PRODUCTS
2.01 GENERAL
A. The Contractor shall furnish and supervise installation of variable frequency drives as described in this specification and as detailed on the applicable Drawings.
B. The Contractor shall be responsible for the erection, installation, and start up of the equipment covered by this specification.
C. The variable frequency drive shall be comply with the latest applicable standards of ANSI, NEMA, IEEE, and the National Electrical Code.
D. Variable frequency drives shall operate as specified on existing or new standby generators or normal power sources.
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E. Variable frequency drives shall be 6 pulse (or greater) for less than 100 HP. If greater than 6 pulse is provided for less than 100 HP, the variable frequency drives shall utilize a phase shift transformer and cancellation technique. Variable frequency drives shall utilize a phase shift transformer and 18 pulse (or greater) cancellation technique for 100 HP and larger.
F. VFD Service Conditions
1. Elevation up to 3,300 feet.
2. Ambient temperature up to 40 degrees Celsius.
3. Relative humidity less than 95 percent, non-condensing.
4. Input voltage variation minus 10 percent to plus 10 percent, maximum 2 percent imbalance.
5. Input frequency variation plus or minus 5 percent.
G. VFD Ratings
1. The rated input power shall be 480 Volts, 3 Phase, 60 Hz.
2. VFD input shall be rated for 65 kA short circuit.
3. The rated output power shall be 480 Volts, 3 phase, 00 to 60 Hz.
4. Output speed regulation shall be plus or minus 0.5 percent, without encode or tachometer feedback.
5. The power unit rating basis shall be 100% rated current continuous.
H. VFD Performance
1. The VFD shall be capable of 110% overcurrent for 1 minute, every 10 minutes for variable torque loads (centrifugal fans, pumps, etc.). The VFD shall be capable of 150% overcurrent for 1 minute, every 10 minutes for constant torque loads (extruders, mixers, reciprocating compressors and pumps, conveyors, etc.).
2. The minimum VFD system efficiency shall be 96% at 100% speed and 100% torque and exceed 90% at 50% speed and load. Variable frequency drive efficiency shall be defined as drive output power at the motor output terminals divided by the input power at the line side of the main circuit breaker.
3. The variable frequency drives shall maintain the line side displacement power factor no less than 0.95 regardless of speed and load.
4. Motor Compatibility:
a. The VFD shall be capable of operating a motor with variable torque type loads with a minimum speed range of 0-60 Hz.
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b. The VFD shall be capable of providing breakaway torque for the pump.
c. VFD system shall provide an output waveform that will allow utilization of standard motors, without need of any special insulation or derating. Motor life expectancy should not be compromised in any way by operation with the VFD system. The system must comply with all elements of the Output Harmonics section of this specification. The VFD must provide motor overload protection in any operating condition.
d. VFD output waveform shall be suitable for operating a standard squirrel cage induction motor without derating or requiring additional service factor.
e. VFD shall inherently protect motor from high voltage dv/dt stress, independent of cable length to motor. The VFD system shall be designed to produce no standing waves or overvoltage conditions based on a maximum cable length of 1,000 feet. Provide an output filter integral to the VFD if required to meet this requirement.
5. The drive shall be capable of riding through a power outage of up to 5 cycle duration, without causing the drive to shutdown.
6. When the power is restored after a complete power outage, the VFD shall be capable of catching the motor while it is still spinning and restoring it to proper operating speed. The variable frequency drives shall be able to determine the motor speed in any direction and resume operation without tripping. If the motor is spinning in the reverse direction, the variable frequency drives shall start into the motor in the reverse direction, bring the motor to a controlled stop, and then accelerate the motor in the preset method of starting.
7. The VFD shall be capable of producing a variable AC voltage/frequency output to provide continuous operation over the normal system 30-100% speed range. The VFD must be capable of sustained operation at 1/10 speed to facilitate checkout and maintenance of the driven equipment. As a commissioning and troubleshooting feature, the VFD power circuit shall be capable of operating without a motor connected to the VFD output.
8. Auto-Restart Capability. The VFD system must be capable of automatically restarting in the event of a momentary loss of power, or a clearing of a drive trip. The VFD system shall provide the user with the choice of automatically restarting or not. The user shall be able to selectively apply this feature to some but not all conditions as appropriate for the specific application.
9. Motor Sound Level. All VFDs must be selected for operation at carrier frequencies at or above 8 kHz without de-rating to provide quiet motor operation. Audible motor noise, while operating under VFD control, shall be limited to 3 dB(A) above the amount of noise generated across the line measured at one meter from the motor. Should the motor generate more audible noise than specified, the VFD manufacturer shall, at no charge, provide sound shielding for the motor such that the installation meets the above performance specification.
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2.02 CONSTRUCTION
A. The variable frequency drives (VFD) shall be rated at 480 VAC input with features and options as specified.
B. The variable frequency drives shall be rated for the HP, full load current and rpm of the motor. The variable frequency drives shall be designed to provide microprocessor-based continuous speed adjustment of three-phase motors. The variable frequency output voltage shall provide constant volts-per-Hertz excitation for the motor up to 60 Hertz. The variable frequency drives shall be optimized for an adjustable or selectable carrier frequency to reduce motor noise. The carrier frequency shall be field adjustable and adjusted by the manufacturer’s field engineer during start up.
C. The variable frequency drives shall be of the Pulse Width Modulated (PWM) design converting the utility input voltage and frequency output via a two-step operation. Variable frequency drives utilizing a third power section are not acceptable. Adjustable Voltage and Current Source variable frequency drives are not acceptable. Transistors shall be used in the inverter section. GTOs and SCRs are not acceptable.
D. The variable frequency drives shall be current regulated. Variable frequency drives permitting instantaneous overcurrent trips other than an output short circuit are not acceptable.
E. Variable frequency drive enclosures shall be NEMA Type 12 freestanding floor-mounted, (100 HP and larger) force ventilated (with replaceable air filters) construction requiring front access only. Variable frequency drives up to 75 HP may be wall mounted type meeting all enclosure rating requirements, etc. specified herein. Variable frequency drives requiring rear access for any maintenance are not acceptable. The cooling air required to dissipate heat generated by the power electronics shall be isolated from all drive electronics. Variable frequency drives using liquid-cooled assemblies in conjunction with associated pumps, piping, and separate remote mounted exchangers are not acceptable. The inverters and converters shall have complete unobstructed front accessibility with easily removable assemblies. The complete enclosure shall maintain a constant height, width and depth. The height for all floor- mounted enclosures shall be 90" high. The enclosures shall include the integral isolation/phase shift transformer (as required) and shall not be more than:
1. Dewatering Centrifuge Feed Pumps 14" in width and 12" in depth and 21" high
F. All variable frequency drive programmable parameters shall be adjustable from a digital operator keypad located on the front door of the variable frequency drive. Parameters shall include:
1. Programmable maximum and minimum frequency.
2. Programmable acceleration and deceleration times.
3. Selectable carrier frequencies, V/Hz, and critical frequency avoidance lockout.
4. Adjustable electronic overload and torque limits.
5. Multiple attempt restart following utility outage or fault condition.
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6. Jog, thread, and preset speeds.
7. Keypad lockout and factory default overrides.
8. Adjustable slip compensation (+/- 5%).
G. The variable frequency drives shall be additionally equipped with a digital operator station mounted on the enclosure front door. Control operator devices and indication lights shall include:
1. Local digital speed control.
2. Hand-Off-Remote control selector switch.
3. LED status lights for each HOR position.
4. Momentary start/stop push buttons utilized with the HOR in “Hand”.
5. Local-Remote speed control selector switch.
6. LED status lights for each Local-Remote position.
7. LED status lights for run, fault, alarm, up-to-speed, power on, and drive ready status.
8. Additional controls as required by Division 11 and 13 and as shown on the drawings. Pump Failure will require pump fail timer (as required). Provide for terminations of remote mounted operator control devices and field devices.
H. The variable frequency drives shall have the following system interfaces:
1. Inputs:
a. Two (2) isolated process control speed reference interfaces to receive and isolate 0-10 Vdc or 4-20 mAdc signals.
b. Dedicated terminal blocks for interface with remote operator and field devices.
c. 120 Vac control to allow variable frequency drives to interface with remote contacts and with two or three-wire control.
d. Additional inputs as required by Division 11 or 13 and as shown on the drawings.
2. Outputs:
a. Two (2) analog output signals 0-10 Vdc or 4-20 mAdc for external metering.
b. Run relay with an isolated set of form C contacts.
c. Dry contact output (N.O.) to indicate protective function trip.
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d. Dry contact output (N.O.) to indicate common alarm.
e. Additional outputs as required by Division 11 or 13 and as shown on the drawings.
I. System Communication
a. Control functions to and from the VFD from the SCADA system shall be hardwired using discrete and analog wiring. Analog 4-20 mA signals shall be provided for input speed control and output speed reference. These shall be optically isolated 4- 20 mA DC signals that can be sent to a remote location.
b. Digital communication to SCADA. Provide a fiber port for interconnection to the SCADA system. Communication protocol shall be Modbus RTU. All necessary cables, connectors, software, hardware, etc. shall be provided as required to interface with the SCADA system.
c. Local communication. Provide an RS-232/RS-485 port, door mounted, to provide for direct serial communication with an IBM compatible computer to for setup or downloading of VFD parameters, fault diagnostics, or data logs.
d. VFD’s shall be provided with interfacing hardware, software, etc. as required for control and monitoring from the plant computer system. The VFD’s shall include serial communications link to the plant computer system via Profibus communication cable as shown on the Instrumentation drawings. The manufacturer shall be responsible for complete coordination and compatibility with the plant computer system specified under Division 13 and the VFD’s. Proof of coordination with Division 13 shall be included with the VFD submittals.
J. Monitoring and Displays:
1. The variable frequency drives shall have a 21-character vacuum fluorescent display indicating monitored functions as described in the following paragraph.
2. The following parameters shall be monitored:
a. Input current (3 phases)
b. Input voltage (3 phases)
c. Output current (3 phases)
d. Output voltage (3 phases)
e. Output frequency
f. Kilowatts
g. Drive temperature
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h. Time
i. Date
j. Motor rpm
k. Eight (8) most recent trips/faults
K. Protection Functions:
1. The variable frequency drives shall have the following protective features (with indication for a. through i.):
a. Speed compensated electronic motor overload current.
b. Undervoltage.
c. Overfrequency.
d. Overtemperature.
e. Ground Fault.
f. DC bus protection.
g. Inrush current limit (adjustable 50 to 150%).
h. Input and output phase loss.
i. Emergency stop pushbutton (Red mushroom head and maintained).
j. Current limiting fuses shall be provided on the input side of the VFDs to protect against fault currents up to 200,000 A sym.
k. The output side of the VFDs shall be equipped with a current limiting reactor to reduce the dv/dt.
l. Phase insensitive to input power.
m. Surge protection from input AC line transients at line side of main circuit breaker.
n. Electrical isolation between the power, control and logic circuits.
o. Drive to be capable of withstanding output terminal line short or open circuits without component failure.
L. Additional Features shall be provided as follows:
1. The variable frequency drives shall be equipped with a flange mounted molded case input circuit breaker (65,000 AIC minimum). The breaker shall be interlocked with the
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enclosure doors to prevent access to the variable frequency drive unless the breaker is in the open position and to prevent moving the breaker to the ON position while the unit door is open. The circuit breaker shall have provisions for padlocking in the open position. Provide mechanical interlocks on doors of auxiliary sections of multi-bay or multi-cubical cabinets. Handle height shall not exceed NEC requirements when VFD is located on 4-inch high housekeeping pad.
2. Fused space heaters with thermostat to minimize condensation potential upon drive shutdown.
3. The variable frequency drives shall be variable torque design. Provide constant torque design as required by Division 11.
4. Variable frequency drives shall be capable of unidirectional operation.
5. Variable frequency drives shall have 115 VAC control power for operator devices.
6. Control relays shall be machine tool type, heavy duty type, industrial grade, 600 volt, 10 amp rating, Square D, Class 8501, Type X, Allen Bradley 700 series or equal.
7. A copper ground bus.
8. Separate door-mounted non-resettable elapsed time meter (0-99999.9 hour) in addition to those specified through the door display.
9. Power unit fan loss protection by automatically switching to a 100% spare cooling fan. Cooling fans shall be on when the variable frequency drive is operating and off when drive is off (fans shall run for a period of time after the variable frequency drive shuts down to dissipate heat and controlled by a thermal switch). If spare cooling fan is not available, provide cooling fan as spare part.
10. All bus and exposed copper shall be tin plated.
11. All floor mounted enclosures shall have complete 18" (minimum) clear space in bottom of the cubical for line, motor and field cable terminations. All wall mounted enclosures shall have complete 12" (minimum) clear space in bottom of the enclosure for line, motor and field cable terminations.
12. A switchable fluorescent light within each floor mounted section of the enclosure.
13. Barriers on terminals that remain energized with the power disconnect OFF.
14. All circuit boards shall be conformal coated to help protect them from hydrogen sulfide gases.
M. Identification
1. All wiring shall be numbered at each end with typed sleeve type labels at each termination. Labels shall correspond to the wiring diagrams. Wiring less than 6 inches may be numbered at only one end.
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2. Provide warning signs on terminals that are energized with the power disconnect OFF.
3. Provide 2-inch by 5-inch, nominal, engraved three-layer laminated plastic master nameplates on each VFD fastened with stainless steel screws or rivets. Nameplates shall be black letters with white background core, 3/8-inch high lettering and shall indicate equipment designation as shown on the Drawings.
4. Provide legend plates or 1-inch by 3-inch engraved nameplates with 1/4-inch lettering for identification of pilot devices and meters.
5. Provide permanent warning signs as follows:
a. "DANGER - HIGH VOLTAGE - KEEP OUT" on all enclosure doors.
b. "WARNING - HAZARD OF ELECTRIC SHOCK - DISCONNECT POWER BEFORE OPENING OR WORKING ON THIS UNIT".
N. The isolation/phase shift transformers shall be provided as follows:
1. Transformers shall be dry type, self ventilated, with insulation for 100 degrees C average temperature rise above 30 degrees C ambient at full continuous operation and shall be suitable for site ambient and altitude. Each shall be equipped with 120 volt single phase space heater(s) for moisture control.
2. Transformer windings shall be copper and exposed copper and bussing shall be tin plated.
3. Impedance shall be selected by the drive system designer.
4. Transformer shall be designed for Inverter duty service with three phase, twelve-pulse or greater static power converter connected to the secondary windings. The increased eddy and stray losses due to harmonic currents shall be minimized and shall be included in the specified temperature rise.
5. A high temperature alarm and indication shall be provided.
6. Standards: The transformer shall meet the general requirements of ANSI C57.12.00 plus the applicable requirements of ANSI C57.18 (since it is for rectifier service). Tests shall be per ANSI C57.12.90. Additional dry type transformer construction requirements:
a. Noise Level: The maximum sound level shall not be excessive and shall conform to NEMA Standard TR27-5.09.
b. Nameplates: Nameplates, warnings, connection diagrams, etc., shall be in accordance with ANSI C57.12.00.
c. Factory Tests: The routine tests listed in ANSI C57.12.00 shall be conducted on all transformers.
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d. Outline Drawings: To include weight, center of gravity, losses at rated load, DC resistance at 25 degrees C. and nameplate data.
7. Transformer shall be integral to VFD enclosure.
2.03 SHOP TESTING
A. All printed circuit boards shall be tested individually prior to assembly to minimize any impact faulty boards may have on delivery schedules and system reliability. Each board shall be heat run tested for a minimum of 16 hours at 50 degrees C, or per manufacturer’s standard test procedure to minimize infant mortality failures. Boards that exhibit drift during the heat run test shall be replaced with boards that have completed the heat run without drift.
B. Power assemblies shall be visually inspected and then HIPOT tested. Complete diagnostics and logic shall be tested. The complete power conversion circuit shall be thoroughly tested at 100% load for a minimum of one hour and then tested for one minute at momentary overload rating, to weed out any potential problems in advance of final system testing.
C. All electronic components, i.e. power transistors, diodes, insulated gate bipolar transistor (IGBT), and micro chips shall be functionally tested to insure reliability.
D. The manufacturer shall test the variable frequency drive with a motor load (full rated) prior to shipment for 4 hours.
E. The variable frequency drive manufacturer shall provide the actual test data and certification that the tests have been completed prior to shipment to the Engineer for approval.
F. The Contractor shall notify the Engineer two weeks prior to all factory tests. The Engineer shall have the option to inspect all tests at the factory.
G. The manufacturer shall test the variable frequency drive with a motor load (full rated) prior to shipment for 4 hours. All printed circuit boards shall be tested at 50 degrees C for 40 hours. The variable frequency drive manufacturer shall provide the actual test data and certification that the tests have been completed prior to shipment to the Engineer for approval.
2.04 SURFACE PREPARATION AND SHOP PAINTING
A. Prior to shop painting, all surfaces shall be thoroughly cleaned, dry, and free from all mill/scale, rust, grease, dirt, and other foreign matter.
B. Variable frequency drive enclosures shall be shop painted.
PART 3 EXECUTION
3.01 INSTALLATION
A. Installation shall be in strict accordance with the manufacturer's instructions and recommendations in the locations shown on the Drawings. Field wiring shall be in accordance with manufacturer's recommendations. Anchor bolts shall be set in accordance with the manufacturer's recommendations.
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3.02 CONTRACTOR FIELDING TESTING
A. Make the following minimum test and checks before the Manufacturer’s representative is called in for start-up and adjustment.
1. Verify that all connections are completed in accordance with shop drawings.
2. Verify supply voltage and phase sequence are correct.
3. Check mechanical and electrical interlocks for proper operation.
4. Test ground connections for continuity and resistance.
5. Where VFD is installed indoors, verify room air conditioning system is in operation.
B. The Manufacturer’s service technician shall perform start-up and adjustment of the VFD system.
3.03 START-UP AND ADJUSTMENT
A. The Contractor shall notify the Engineer two weeks prior to all field tests. The Engineer shall have the option to witness all tests in the field.
B. Field Tests:
1. Field tests of the drive shall be made by the manufacturer who will furnish all equipment and record all data. The Contractor shall be present during testing.
2. Field tests are the basis of demonstrating equipment proficiency and correct operation.
3. If the drive performance does not meet the Specifications, corrective measures shall be taken or the drive shall be removed and replaced with a drive which satisfies the conditions specified. A seven (7) day 24 hour (actual operation) operating period as specified herein of the drive will be required before acceptance. The Contractor shall provide for seven (7) day 24 hour (minimum) on-site supervision of the field acceptance tests. If a drive fails to perform and must be replaced, the rejected drive shall not be removed until the replacement drive has been delivered to the site. If corrective measures are to be taken, such measures shall be done on-site at such times as convenient to the Owner. The Owner shall be allowed to use any drive supplied immediately following installation and testing whether or not the equipment meets the conditions specified.
4. Factory representatives of the manufacturer who are competent and experienced and who have complete knowledge in the proper operation and maintenance of the equipment shall be provided to inspect and supervise the installation of the equipment and supervise the initial test run. The first visit will be for checking and inspecting the equipment during installation. The second visit will be to operate and supervise the initial field test. If problems are encountered in operation of the equipment additional service shall be provided at no additional cost to the Owner. These services are in addition to the services required for training.
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5. Training will not be permitted until all equipment is fully operational. In the event that the equipment becomes inoperable under warranty provisions, additional training will be provided at no additional cost to the Owner as follows:
Inoperable Period Additional Training
0-2 weeks None 2-6 weeks 2 days More than 6 weeks 5 days
6. All training shall be coordinated and conducted concurrently with training to be supplied by the equipment and motor manufacturers.
7. Functional Test: Prior to plant start-up, all equipment described herein shall be inspected for proper alignment, quiet operation, proper connection, and satisfactory performance by means of a functional test. Submit test procedure for review and approval by the Engineer.
8. Vibration Test: Vibration analyses shall be performed on the equipment when operating the variable frequency drive through its entire speed range. Where loads and drives are separated by intermediate flexible shafting, vibration shall be measured both at the top motor bearing and at two points on the equipment bearing, 90 degrees apart.
9. Performance Testing: Demonstrate system performance by operating the system for a seven (7) day continuous period while varying the application load, as the input conditions allow, to verify system performance. Record all data necessary to document the successful performance of the system. Provide all instruments, equipment, and labor required to accomplish this test. If a unit fails the performance test, the supplier will be allowed to readjust and retest the system. If the unit fails the second test, the unit will be rejected and the Contractor shall furnish a unit that will perform as specified.
10. Check each alarm and detection device for proper operation.
11. The drive manufacturer shall provide all necessary personnel and equipment necessary to properly start-up and pass all tests at no additional cost to Owner.
12. A copy of all tests and checks performed in the field complete with meter readings and recordings, where applicable, shall be submitted to the Engineer.
3.04 CLEANING
A. Remove all rubbish and debris from inside and around the equipment. Remove dirt, dust or concrete spatter from the interior and exterior of the equipment using brushes, vacuum cleaner or clean lint-free rags. Do not use compressed air.
END OF SECTION
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SECTION 16470
PANELBOARDS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required and install all panelboards as shown on the Drawings and as specified herein.
B. All panelboard wiring shall include wiring numbers and terminal point numbers cross referenced to shop drawing and subsequent record drawing submittals.
1.02 SUBMITTALS
A. Submit to the Engineer, in accordance with Section 01300, shop drawings and product data, for the following as a minimum:
1. Equipment outline drawings showing elevation and plan views, dimensions and weight. Indicate all options, special features, ratings and deviations from this Section.
2. Bus arrangement drawings.
3. Product data sheets and catalog numbers for circuit breakers, etc. List all options, trip adjustments and accessories furnished specifically for this project.
4. Instruction and renewal parts books.
5. Test and inspection reports.
6. Complete bill of materials list.
7. The equipment drawings, summary tables, and bill of materials list shall be computer generated (i.e. no hand-drawn drawings, sketches, lists will be accepted).
1.03 REFERENCE STANDARDS
A. Panelboards shall be in accordance with the Underwriter Laboratories (UL) "Standard for Panelboards" and "Standard for Cabinets and Boxes" and shall be so labeled where procedures exist. Panelboards shall also comply with NEMA Standard for Panelboards and the National Electrical Code (NEC).
B. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.
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1.04 MANUFACTURERS
A. 120/240 Volt, single phase, 3 Wire and 120/208 Volt, 3 Phase, 4 Wire panelboards shall be Type NQOD as manufactured by Square D; Type Pow-R-Line by Cutler Hammer; Type AQ by General Electric; or P Series by Siemens.
B. 277/480 Volt, 3 Phase, 4 Wire panelboards shall be; Type NF as manufactured by Square D; Type Pow-R-Line by Cutler Hammer; Type AE by General Electric; or P Series by Siemens.
C. 480 Volt, 3 Phase, 3 Wire panelboards shall be; I-Line series as manufactured by Square D; Type Pow-R-Line by Cutler Hammer; Type Spectra by General Electric; or P Series by Siemens.
D. NEMA 3R and 4X panelboards shall be as specified herein, provided in 316 stainless steel enclosures as manufactured by the Hoffman or equal and completely assembled by the panelboard manufacturer.
E. Refer to additional requirements for manufacturers in Section 16000. Alternate suppliers must be submitted for approval to the Engineer in writing four weeks prior to the original bid date with supporting documentation to confirm all aspects of the specifications.
PART 2 PRODUCTS
2.01 GENERAL
A. Rating
1. Panelboard ratings shall be as shown on the Drawings. All panelboards shall be rated for the intended voltage.
2. Circuit breaker panelboards shall be fully rated for the specified circuit breaker fault current interrupting capacity. Series connected short circuit ratings will not be acceptable.
2.02 MATERIALS (NEMA 1)
A. Interiors
1. All interiors shall be completely factory assembled with circuit breakers, wire connectors, etc. All wire connectors, except screw terminals, shall be of the anti-turn solderless type and all shall be suitable for copper wire of the sizes indicated.
2. Interiors shall be so designed that circuit breakers can be replaced without disturbing adjacent units and without removing the main bus connectors and shall be so designed that circuits may be changed without machining, drilling or tapping.
3. Branch circuits shall be arranged using double row construction except when narrow column panels are indicated. Branch circuits shall be numbered by the manufacturer.
4. A nameplate shall be provided listing manufacturer's name, panel type and rating.
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B. Buses
1. Bus bars for the mains shall be of tin plated copper. Full size tin plated copper neutral bars shall be included. Bus bar taps for panels with single pole branches shall be arranged for sequence phasing of the branch circuit devices. Bussing shall be braced throughout to conform to industry standard practice governing short circuit stresses in panelboards. Phase bussing shall be full height without reduction. Cross connectors shall be tin plated copper. Each panel shall be provided with a ground bus bar, with removable link/jumper between neutral and ground bus. The ground bus shall be sized to the maximum number of circuit breakers that can be installed in the panelboard.
2. Neutral bussing shall have a suitable lug for each outgoing feeder requiring a neutral connection.
3. Spaces for future circuit breakers shall be bussed for the maximum device that can be fitted into them.
4. Tin plated copper equipment ground bars shall be furnished.
C. Boxes
1. Recessed or flush mounted boxes shall be made from galvanized code gauge steel having multiple knockouts, unless otherwise noted. Boxes shall be of sufficient size to provide a minimum gutter space of 4-in on all sides.
2. Surface mounted boxes and trims shall have an internal and external finish as specified in Paragraph 2.04D4 below.
3. At least four studs for mounting the panelboard interior shall be furnished.
4. All conduit entrances shall be field punched.
D. Trim
1. Hinged doors covering all circuit breaker handles shall be included in all panel trims.
2. Doors shall have semi flush type cylinder lock and catch, except that doors over 48-in in height shall have a vault handle and 3-point catch, complete with lock, arranged to fasten door at top, bottom and center. Door hinges shall be concealed. Furnish two keys for each lock. All locks shall be keyed alike; directory frame and card having a transparent cover shall be furnished on each door. All trims shall be door-in-door type construction.
3. The trims shall be fabricated from code gauge sheet steel.
4. All exterior and interior steel surfaces of the panelboard shall be properly cleaned and finished with ANSI Z55.1, No. 49 or 61 light gray paint over a rust-inhibiting phosphatized coating. The finish paint shall be of a type to which field applied paint will adhere.
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5. Trims for flush panels shall overlap the box by at least 3/4-in all around. Surface mounted panel trims shall have the same width and height as the box. Trims shall be fastened with quarter turn clamps.
2.03 MATERIALS (NEMA 3R and 4X)
A. Interiors and Buses
1. Interiors and buses shall be as hereinbefore specified for NEMA 1 construction.
B. Boxes and Covers
1. Boxes, covers and hardware shall be made from 316 stainless steel with natural finish.
2.04 Boxes and covers shall have continuous welded seams and shall be hinged (piano type) together and gasketed.
1. Conduit openings shall be tapped.
2.05 CIRCUIT BREAKERS
A. Panelboards shall be equipped with circuit breakers with frame size and trip settings as shown on the Drawings.
B. Circuit breakers shall be molded case, bolt-in type.
C. Each circuit breaker used in 120/208 Volt panelboards shall have an interrupting capacity of not less than 10,000 Amps, RMS symmetrical.
D. Each circuit breaker used in 120/240 Volt and 120/208 Volt panelboards shall have an interrupting capacity of not less than 10,000 Amps, RMS symmetrical.
E. Each circuit breaker used in 277/480 Volt and 480 Volt panelboards shall have an interrupting capacity of not less than 65,000 Amps, RMS symmetrical.
F. GFCI (ground fault circuit interrupter) shall be provided for circuits as required and where indicated the Drawings. GFCI units shall be 1 Pole, 120 Volt, molded case, bolt-on breakers, incorporating a solid state ground fault interrupter circuit insulated and isolated from the breaker mechanism. The unit shall be UL listed Class A Group I device (5 milliamp sensitivity, 25 millisecond trip time) and an interrupting capacity of 10,000 Amps, RMS.
G. Circuit breakers shall be manufactured by the panelboard manufacturer.
PART 3 EXECUTION
3.01 INSTALLATION
A. Mount boxes for surface mounted panelboards so there is at least 1/2-in air space between the box and the wall.
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B. Connect panelboard branch circuit loads so that the load is distributed as equally as possible between the phase busses. Record normal base load phase voltages and currents for each phase and the total neutral current and submit to the Engineer for review.
C. Install markers on the front cover of all panelboards which identify the voltage rating. Markers shall be made of self sticking B-500 vinyl cloth printed with black characters on an Alert Orange background, 2-1/4-in high by 9-in wide, Style A as manufactured by W.H. Brady Co. or equal.
D. Install a 1-in by 3-in nominal laminated plastic nameplate with 1/2-in white letters on a black background on each panelboard. Nameplate lettering shall be as shown on the Drawings. Nameplates shall be stainless steel screw mounted.
E. Unless otherwise noted on the Drawings, top of cabinets shall be mounted 6 feet-0-inch above the floor, properly aligned and adequately supported independently of the connecting raceways.
F. All wiring in panelboards shall be neatly formed, grouped, and identified to provide a neat and orderly appearance. A typewritten directory card identifying all circuits shall be placed in the card holder inside the front cover.
G. All panelboards shall be protected from physical damage, water damage, moisture, corrosion, dirt and dust during construction. Any panelboard judged to be unacceptable by the Engineer shall be replaced by the Contractor at no additional cost to the Owner.
H. Standard factory testing shall be performed for the equipment furnished under this section and these tests shall be in accordance with the latest version of NEMA and UL standards. Certified copies of these tests shall be provided to the Engineer upon request.
I. Field testing and commissioning shall be done in accordance with the latest revision of the "Acceptance Testing Specifications for Electrical Power Distribution Equipment and Systems" published by the InterNational Electrical Testing Association (NETA Standard ATS-2007) unless otherwise modified by this Section.
3.02 CLEANING
A. Remove all rubbish and debris from inside and around the equipment. Remove dirt, dust or concrete spatter from the interior and exterior of the equipment using brushes, vacuum cleaner or clean lint-free rags. Do not use compressed air.
END OF SECTION
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SECTION 16500
LIGHTING SYSTEM
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required and install a complete lighting system ready for operation as shown on the Drawings and as specified herein.
1.02 RELATED WORK
A. All concrete and reinforcing steel required for exterior lighting pole bases shall be as specified under Division 3, but the responsibility of furnishing and installing the material shall be that of Division 16.
B. Conduit is included in Section 16110.
C. Wire is included in Section 16120.
D. Transformers are included in Section 16191.
E. Panelboards are included in Section 16470.
1.03 SUBMITTALS
A. Submit, in accordance with Section 01300. Submittals shall include those set forth in Section 16000, Paragraph 1.03.
1.04 REFERENCE STANDARDS
A. All lighting fixtures shall be in accordance with the National Fire Protection Association (NFPA) NFPA 70 “National Electrical Code” (NEC) and shall be constructed in accordance with the latest edition of the Underwriters Laboratories (UL) "Standards for Safety, Electric Lighting Fixtures."
B. All lighting fixtures shall be UL labeled. Lighting equipment shall comply with UL standards pertaining to luminaires including: UL 1570 Fluorescent Lighting Fixtures; UL 1598 HID Lighting Fixtures; UL 1029 HID Ballasts; UL 542 Lampholders, Starters and Starter Holders for Fluorescent Lamps and UL 844 Standard for Electric Lighting Fixtures for Use in Hazardous (Classified) Locations
C. Comply with all relevant Federal, State, Local, and Agency guidelines when disposing of lighting waste:
D. Most fluorescent, compact fluorescent, and HID lamps require special handling and disposal procedures. Most ballasts containing PCB’s require special handling and disposal procedures. Disposal guidelines are available on the internet from the US Environmental Protection Agency at www.epa.gov
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E. Low mercury lamps shall be defined as passing the Toxic Characteristic Leaking Procedure (TCLP) test established by the U.S. Environmental Protection Agency (EPA).
PART 2 PRODUCTS
2.01 MATERIALS
A. Luminaires (Lighting Fixtures)
1. Luminaire types shall be furnished as required by the "Lighting Fixture Schedule" on the Drawings. The catalog numbers are given as a guide to the design and quality of fixture desired. Equivalent designs and equal quality fixtures of other manufacturers will be acceptable upon approval by the Engineer.
B. Lamps
1. Fluorescent Lamps
a. Fluorescent lamps shall be low mercury, tri-phosphors with a correlated color temperature (CCT) of 3500 Kelvin and a color rendering index (CRI) of not less than 80 CRI. Compact types are as shown on the "Lighting Fixture Schedule".
b. HID (Metal Halide and High Pressure Sodium) Lamps
1) Lamps shall be designed for operation with the specified ballast assembly
2) Lamp shall be designed for operation in the specified mounting position.
3) HPS Lamps shall have two arc tubes so that instant restrike will occur in the event of a momentary power failure.
4) Rated lamp life shall be a minimum or 24,000 hours for HPS lamps based on three-hour starts.
5) Rated lamp life shall be a minimum or 20,000 hours for MH lamps based on three-hour starts.
6) Lamps shall be clear or coated, as specified on the “Lighting Fixture Schedule” or as required for proper luminaire performance.
7) Incandescent lamps shall be inside frosted, halogen, 2,500 hour minimum life. Size and type shall be as shown on the “lighting fixture schedule.”
8) Metal Halide lamps shall be ANSI Type O, open-rated protected lamps for use in open or enclosed luminaires. Lamps shall have exclusionary base for use in standard or protected type mogul sockets. .
9) All lamps shall be of one manufacturer and shall be as manufactured by Osram Sylvania; General Electric; Philips or equal.
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C. Ballasts
1. Program Rapid Start Fluorescent Ballasts
2. Provide energy efficient fluorescent ballasts conforming where relevant to UL 935, "Fluorescent-Lamp Ballasts," ANSI C82.1, "Ballasts for Fluorescent Lamps Specification," ANSI C82.11, "High Frequency Fluorescent Lamp Ballasts," and ANSI C82.2 "Methods of Measurement of Fluorescent Lamp Ballasts," ANSI NFPA 70, and Public Law 100-357 National Appliance Energy Conservation Amendment of 1988, as applicable.
3. Shall be electronic (solid state) Program Rapid Start Ballast and have a Certified Ballast Manufacturer (CDM) label, unless noted otherwise.
4. All ballasts used in exterior applications or areas where ambient temperatures may fall below 50 degrees F shall have a minimum starting temperature of 0 degrees F unless otherwise specified.
5. All interior ballasts shall have a minimum starting temperature of 50 degrees F.
6. Ballasts shall be series wired type and designed to operate the number and length of lamps specified.
7. The total harmonic distortion (THD) of each ballast shall be in accordance with the requirements of the utility company and in no case shall it be greater than 10 percent THD.
8. Use Class "P" thermal protected ballasts.
9. Ballasts shall be of high power factor, with a power factor of 0.9 or greater.
10. Ballasts shall have a maximum lamp current crest factor of 1.7.
11. Light output (ballast factor) shall be between 0.85 and 1.0 when tested with a compatible full-wattage lamp (T-8 OR T-5).
12. Ballast shall be regulated to maintain light output which does not vary more than ± 5% for all rapid start fluorescent lamps in the proper lamp/ballast combination within operating ranges of ± 10% of center voltage.
13. Cathode voltage for rapid start lamps during starting shall be between 3.4 and 4.5V across a dummy load and between 2.5 and 4.4V during operation. Ballast shall have a frequency of operation of 40 kHz or greater and incorporate adequate 60 Hz filtering in order to operate with less than 5% flicker (maximum 0.20 Flicker Index) with any rare earth phosphor lamp suitable for the ballast.
14. Ballast shall provide normal rated life for the lamp specified.
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15. All electronic ballasts shall be warranted for parts and replacement for 1 full year from the date of installation.
16. Ballasts shall have an "A" sound rating or better.
17. Ballast shall not contain polychlorinated biphenyls (PCBs) and shall be labeled “NO PCBS.”
18. Ballasts shall be designed to operate on the voltage system to which they are connected and designated by the ballast manufacturer as suitable and UL listed for operating the specified lamps
19. Ballasts shall meet the requirements of the Federal Communications Commission Rules and Regulations, Part 18, Subpart C (RF Lighting Devices), regarding radio frequency interference (RFI) and electromagnetic interference (EMI).
20. Electronic fluorescent ballasts shall be universal voltage type capable of operating from 110V to 302V rms input.
21. Electronic ballasts shall be as manufactured by Advance, similar by Osram Sylvania; Universal Lighting or equal.
22. Electronic (Solid State) Instant start Fluorescent Ballasts:
a. In addition to the requirements of 2.01 C.1., electronic instant start ballasts shall meet or exceed the following criteria:
1) Ballast shall meet all relevant ANSI specifications, and have CBM label.
2) Light output (ballast factor) shall be between 0.85 and 1.0 when tested with a compatible full-wattage lamp (40W T-12, T-8, OR T-5).
3) Ballast shall be regulated to maintain light output which does not vary more than ± 5% for all rapid start fluorescent lamps in the proper lamp/ballast combination within operating ranges of ± 10% of center voltage. (e.g. 120 V or 277 V).
4) Rated lamp life shall not be reduced more than 25% compared with rapid start operation, based on three hours per start.
5) Multi-lamp ballasts shall operate lamps in parallel, so that when one lamp burns out the other lamps will continue operating at full light output.
6) Electronic ballasts shall be as manufactured by Advance, Osram Sylvania; Universal Lighting or equal.
23. HID (Metal Halide and High Pressure Sodium) Ballasts
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a. Ballast assemblies shall be designed to operate at the specified voltage, and designated by the ballast manufacturer as suitable and UL listed for operating the specified lamps.
b. Lamp current crest factor shall not exceed 1.8.
c. Ballast assemblies shall be capable of starting and operating the specified lamps within a range of +10% of the specified voltage.
d. Total Line Current Harmonic Distortion shall not exceed 33%.
e. Electronic ballast assemblies shall meet the requirements of the Federal Communications Commission Rules and Regulations, Part 18, Subpart C (RF Lighting Devices), regarding radio frequency interference (RFI) and electromagnetic interference (EMI).
f. Ballast shall be of high power factor or power factor corrected type, with a power factor of 0.9 or greater.
g. Insulation shall be Class 180 degree C minimum.
h. Ballast assemblies shall start lamps at a minimum temperature of -20° Fahrenheit.
i. In addition to the above stated HID Ballast requirements, High pressure sodium ballasts shall be of the constant wattage auto-transformer type of the correct size and voltage for the fixture it is to serve as shown on the "Lighting Fixture Schedule". All ballasts shall be as manufactured by Advance Transformer Co., similar by Holophane Lighting; Universal Manufacturing; Osram Sylvania or equal.
j. In addition to the above stated HID Ballast requirements, Metal halide ballasts shall be Pulse Start of the constant wattage auto-transformer type of the correct size and voltage for the fixture it is to serve as shown on the "Lighting Fixture Schedule". All ballasts shall be as manufactured by Advance Transformer Co., Holophane Lighting; Universal Manufacturing; Osram Sylvania or equal
D. Wiring Devices
1. Switches, receptacles and other devices shall be gray.
2. Wall switches shall be of the indicating, toggle action, flush mounting quiet type. All switches shall conform to Federal Specification WS896-E. Wall switches shall be the manufacturer’s “industrial specification grade”. Wall switches shall be the following types and manufacturer or approved equal.
a. Single pole - Arrow-Hart, Series 1991, or approved equal by Harvey Hubbell, Inc., Pass & Seymour, Inc., or approved equal.
b. Double pole - Arrow-Hart, Series 1992, or approved equal by Harvey Hubbell, Inc., Pass & Seymour, Inc., or approved equal.
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c. Three way - Arrow-Hart, Series 1993, or approved equal by Harvey Hubbell, Inc., Pass & Seymour, Inc., or approved equal.
d. Four way - Arrow-Hart, Series 1994, or approved equal by Harvey Hubbell, Inc., Pass & Seymour, Inc., or approved equal.
e. Single pole, key operated - Arrow-Hart Catalog Number 1991-L, or approved equal.
f. Single pole, pilot indicating, Bryant Catalog Number 4901-PLR120, or approved equal by Harvey Hubbell, Inc., Pass & Seymour, Inc., or approved equal.
g. Momentary contact, 2 circuit, center off - Arrow-Hart, Series 1895, or approved equal by Harvey Hubbell, Inc., Pass & Seymour, Inc., or approved equal.
h. Weatherproof cover for standard toggle switches - Crouse-Hinds Catalog Number DS181, or approved equal by Appleton Electric Co., L.E. Mason Co., or approved equal.
i. Explosion-proof single pole switches shall be for 20 amperes, 120/277 volts, mounted in cast boxes and be similar and equal to Crouse-Hinds EDS Series, or approved equal by Appleton Electric Co., L.E. Mason Co., or approved equal.
3. Receptacles shall be the manufacturer’s “industrial specification grade”. Receptacles shall be of the following types and manufacturer or approved equal. Receptacles shall conform to Federal Specification WC596-F.
a. Duplex, 20A, 125V, 2P, 3W; Arrow-Hart, Series 5362, or approved equal by Harvey Hubbell, Inc., Pass & Seymour, Inc., or approved equal.
b. Weatherproof or corrosion resistant single, 20A, 125V, 2P, 3W; by Harvey Hubbell, Inc., Pass & Seymour, Inc., with TayMac Corp., #30310G cover, or approved equal.
c. Weatherproof or corrosion resistant duplex, 20A, 125V, 2P, 3W; by Harvey Hubbell, Inc., Pass & Seymour, Inc., with TayMac Corp., #10310G cover, or approved equal.
d. Ground fault interrupter, duplex, 20A, 125V, 2P, 3W; Arrow-Hart Series GF 5342, or approved equal by Harvey Hubbell, Inc., Pass & Seymour, Inc., or approved equal.
e. Duplex, 20A, 125V, 2P, 3W with transient voltage surge suppressor and indicator light; Pass & Seymour Series 6362-5P, approved equal by Harvey Hubbell Inc., Bryant Electric Co., or approved equal.
f. Stainless steel indoor mounting plate for G.F.I. receptacle; Arrow-Hart Catalog Number 97061, or approved equal by Harvey Hubbell, Inc., Pass & Seymour, Inc. or approved equal.
g. Weatherproof cover for G.F.I. receptacle shall be TayMac Corp., #20310G, or approved equal.
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h. Explosion-proof, 20A, 125V, 2P, 3W; Appleton Electric Co. Catalog Number EFS175-2023 or EFSC175-2023 or approved equal by Crouse-Hinds Co., Killark Electric Manufacturing Co., or approved equal. Furnish one Appleton Electric Co. Catalog Number ECP-1523 cap or approved equal by Crouse-Hinds Co., Killark Electric Manufacturing Co., or approved equal for every two receptacles (minimum of one).
i. Single, 20A, 250V, 2P, 3W; Arrow-Hart Catalog Number 5861, or approved equal by Harvey Hubbell, Inc., Pass & Seymour, Inc., or approved equal.
j. Single, 30A, 125V, 2P, 3W; Arrow-Hart Catalog Number 5716; cap: Arrow-Hart Catalog Number 5717.
k. Single, 30A, 250V, (3 phase) 3P, 4W; Arrow Hart Catalog Number 8430N; Cap: Arrow-Hart Catalog Number 8432AN.
4. Device Plates for flush mounted devices shall be of the required number of gangs for the application involved and shall be:
a. Smooth high strength thermoplastic or nylon of the same manufacturer as the device for all administrative office type areas. Color to match device.
b. Type 302 (18-8) high nickel stainless steel of the same manufacturer as the device for all other areas.
c. Plates for surface mounted device boxes shall be of the same material as the box.
PART 3 EXECUTION
3.01 INSTALLATION
A. Each fixture shall be a completely finished unit with all components, mounting and/or hanging devices necessary, for the proper installation of the particular fixture in its designated location and shall be completely wired ready for connection to the branch circuit wires at the outlet.
B. All flush mounted fixtures shall be supported from the structure and shall not be dependent on the hung ceilings for their support.
C. Fixtures noted to be installed flush in suspended ceilings shall be of mounting types suited for the type ceiling involved. It shall be the responsibility of the electrical contractor to verify the ceiling types prior to ordering fixtures.
D. Flexible fixture hangers shall be used for all pendant mounted fixtures. Fixtures 2-ft long and larger shall be supported with a minimum of two fixture hangers.
E. Conduit run in areas with hung ceilings shall be installed in the space above the hung ceiling as close to the structure as possible. Conduits shall be supported from the structure.
F. Exterior lighting poles shall be mounted plumb.
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G. Fixture locations are shown on the Drawings in approximate locations; however exact locations shall be coordinated so as to avoid conflicts with HVAC ducts, equipment and other obstacles.
H. Where the Drawings state a particular mounting height, it shall imply that the bottom of the fixture shall be mounted at the stated mounting height above the finished floor, unless specifically noted otherwise.
I. The minimum mounting height for the bottom of lights and exit signs shall be 80” above the finished floor in compliance with Americans with Disabilities Act (ADA).
J. Provide circuit identification at devices as specified in Section 16000.
3.02 REPLACEMENT
A. Lamps (except for HID) used during the building construction, prior to 2 weeks from completion of the work, shall be removed and replaced with new lamps.
B. Metal halide lamps that produce a green, blue, or pink color shift after 100 hours of operation shall be replaced at no additional cost to the Owner.
3.03 CLEANING UP
A. Plastic dust cover bags to be provided with new parabolic reflector lighting fixtures shall be removed after all construction activity that may cause dust formation on reflector surfaces has been completed.
B. All fixtures shall be left in a clean condition, free of dirt and defects, before acceptance by the Engineer.
END OF SECTION
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SECTION 16600
UNDERGROUND SYSTEM
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish and install a complete underground system of raceways, manholes and handholes as shown on the Drawings and as specified herein. This work includes all underground raceways which are direct buried or concrete encased.
1.02 RELATED WORK
A. All concrete and reinforcing steel shall be as specified in Division 3, but the responsibility of furnishing and installing the material shall be that of this Section.
B. All trenching, excavation and backfilling, including gravel and sand bedding and surface restoration shall be as specified in Division 2, but the responsibility of furnishing and installing the material shall be that of this Section.
C. Conduit, fittings, installation, etc. shall be as specified in Section 16110.
D. Ground rods and other grounding materials and methods shall be as specified in Section 16660.
E. Precast electrical concrete manholes and handholes shall be furnished under Division 16 and shall be in compliance with precast concrete structures as specified in Section 02605.
1.03 SUBMITTALS
A. Submit to the Engineer, in accordance with Section 01300, shop drawings and product data, for the following:
1. Manholes and handholes
2. Plastic duct spacers
3. Manhole and handhole frames and covers
PART 2 PRODUCTS
2.01 MATERIALS
A. Cable racks, supports, pulling-in irons, manhole steps and hardware shall be hot dipped galvanized steel as manufactured by Line Materials Co. or equal.
B. Precast concrete manholes and handholes shall be heavy duty type, designed for a Class H20 wheel load. Precast manholes and handholes shall be as manufactured by Brooks Products Co.
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C. Manhole frames and covers shall be cast iron heavy duty type for class H-20 wheel loading, and shall be as manufactured by Neenah, or equal. Manhole covers shall be marked “ELECTRIC”.
D. Handhole covers and frames shall be hot dipped galvanized and designed for a Class H-20 wheel load. Handhole covers and hatches shall have 316 stainless steel security bolts. Handhole covers shall be marked “ELECTRIC”.
E. Bell ends and plastic duct spacers shall be as manufactured by Carlon or equal.
PART 3 EXECUTION
3.01 INSTALLATION
A. Install raceways to drain away from buildings. Raceways between manholes or handholes shall drain toward the manholes or handholes. Raceway slopes shall not be less than 3-in per 100-ft.
B. Reinforce raceway banks as shown on the Drawings.
C. Lay raceway lines in trenches on a clean backfill bedding not less than 6 inches thick and well graded and compacted.
D. Use plastic spacers located not more than 4-ft apart to hold raceways in place. Spacers shall provide not less than 2-in clearance between raceways.
E. The minimum cover for raceway banks shall be 30-in unless otherwise permitted by the Engineer.
F. Make raceway entrances to buildings and vaults with hot dipped rigid galvanized steel conduit not less than 10-ft long. Conduits which are not concrete encased for runs below floor slabs in slab-on-grade construction shall be PVC coated hot dipped rigid galvanized steel conduit. Conduits which are concrete encased for runs below floor slabs in slab-on-grade construction shall be encased under the slab to their respective equipment.
G. Raceway terminations at manholes shall be with end bells for PVC conduit and insulated throat grounding bushings with lay-in type lugs for metal conduit.
H. For bends in 2 inch and larger raceways, long radius elbows, sweeps and offsets shall be used.
I. All 2 inch and larger raceways shall have a mandrel drawn through followed by a swab to clean out any obstructions which may cause cable abrasions. The mandrel shall be 12 inches in length and the diameter 1/2 inch less than the inside diameter of the raceway. All 1-1/2 inch and smaller raceways shall be swabbed clean before installing cables.
J. Plug spare raceways and seal them watertight at all buildings and structures.
K. Raceways in use shall be sealed watertight at all buildings and structures.
L. Install pulling-in irons opposite all raceway entrances to manholes.
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M. Cables shall be trained in manholes and supported on racks and hooks at intervals not greater than 3 feet-0 inches and supports shall be installed on each side of all splices. Furnish inserts on all manhole walls for mounting future racks as well as racks required for present installation. Branch circuit conductors shall not be run in manholes.
N. All joints shall be made so as to prevent the passage of concrete inside the conduit to form obstructions or cause cable abrasions.
O. Manhole covers in streets shall finish flush with finished paving and in other areas shall finish 3 inches above crown of adjacent roadway. Floor elevations of manholes shall be so set that the center line of the lowest conduit entering will be not less than 1-foot above the floor and center line of the highest conduit entering will be not less than 1 foot below the roof slab.
P. Concrete monuments shall be provided at each stubbed conduit location. Monuments shall be as shown on the Drawings and shall be installed in the same manner outlined for manhole covers.
Q. A #6 bare copper wire (stranded) shall be installed in each 4-inch PVC conduit containing control cable unless otherwise noted.
R. A 3/4-inch by 10-foot copperclad ground rod shall be driven in the bottom of each manhole. All bond wires, galvanized conduits and metal cable racks shall be bonded to the ground rod.
S. Polyethylene warning tape shall be provided for all underground raceways, duct banks etc. Tape shall be placed along the raceways entire length and shall be installed 18" above the raceways on compacted backfill material.
T. Spare and empty conduits shall have a pull wire (3/16 inch polypropylene) installed.
U. As-built drawings shall be furnished showing each conduit terminations, elevations, locations, manholes, handholes, etc.
END OF SECTION
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SECTION 16660
GROUNDING SYSTEM
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required and install a complete grounding system in strict accordance with Article 250 of the National Electrical Code (NEC), as shown on the Drawings and as specified herein.
B. All raceways, conduits and ducts shall contain equipment grounding conductors sized in accordance with the NEC. Minimum sizes shall be No. 12 AWG.
1.02 SUBMITTALS
A. Submit to the Engineer, in accordance with Section 01300, shop drawings and product data, for the following:
1. Manufacturer's name and catalog data for ground rods, materials and exothermic welding methods and materials.
PART 2 PRODUCTS
2.01 MATERIALS
A. Conduit shall be as specified under Section 16110.
B. Wire shall be as specified under Section 16120.
C. Ground rods shall be 3/4-in diameter by 10-ft copper clad steel and constructed in accordance with UL 467. The minimum copper thickness shall be 0.25 mm (10 mil). Ground rods shall be Copperweld or equal.
D. Grounding conduit hubs shall be malleable iron type, manufactured by Thomas & Betts Co.; Catalog No. 3940 (3/4-in conduit size), similar to Burndy; O.Z./Gedney Co. or equal, and of the correct size for the conduit.
E. Waterpipe ground clamps shall be cast bronze saddle type, manufactured by Thomas & Betts Co. Cat. No. 2 (1/2-in, 3/4-in, or 1-in size), similar by Burndy; O.Z./Gedney Co. or equal, and of the correct size for the pipe.
F. Buried grounding connections shall be by Cadweld process, or equal exothermic welding system.
G. Ground Enhancement Material (GEM) shall be a low-resistance, non-corrosive, carbon dust based material that improves grounding effectiveness. GEM shall contain cement, which hardens when set to provide a permanent, maintenance-free, low-resistant grounding system
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that never leaches or washes away. GEM shall be suitable for installation in trenches or backfilling around ground rods. GEM shall have a resistivity of no more than 20 ohm-cm. GEM shall be ERICO Part No. GEM25A or equivalent.
PART 3 EXECUTION
3.01 INSTALLATION
A. The service entrance equipment ground bus shall be grounded to a ¾-inch cold water pipe and to the ground as indicated on the Drawings. Run grounding electrode conductors in Schedule 80 PVC conduits and seal conduits watertight. Do not allow water pipe connections to be painted. If the connections are painted, disassemble them and re-make them with new fittings.
B. Install equipment grounding conductors with all feeders and branch circuits.
C. Bond all steel building columns in new structures together with ground wire in rigid conduit and connect to the distribution equipment ground bus, as shown on the Drawings.
D. Ground wire connections to structural steel columns shall be made by exothermic welding.
E. Metal conduits stubbed into a motor control center shall be terminated with insulated grounding bushings and connect to the motor control center ground bus. Bond boxes mounted below motor control centers to the motor control center ground bus. Size the grounding wire in accordance with NEC Table 250.122, except that a minimum No. 12 AWG shall be used.
F. Ground bus in all motor control centers and unit substations shall be connected to the service entrance equipment ground bus with a No. 1/0 conductor or as noted on the Drawings.
G. Ground transformer neutrals to the nearest available grounding electrode with a minimum conductor sized in accordance with NEC Article 250 or as shown on the drawings.
H. Grounding electrodes shall be installed vertically and not allowed to be deformed or driven at an angle. Where driving is difficult or where rock is encountered, Contractor shall use purpose-designed drilling equipment, install the rod into the drilled hole and backfill around rod using ground enhancement material (GEM) mixed with water to form a slurry in accordance with the Manufacturer’s instructions.
I. Install ground grids as shown on the Drawings.
J. All equipment enclosures, motor and transformer frames, conduits systems, cable armor, exposed structural steel and all other equipment and materials required by the NEC to be grounded, shall be grounded and bonded in accordance with the NEC.
K. Seal exposed connections between different metals with No-Oxide Paint Grade A or equal.
L. Lay all underground grounding conductors slack and, where exposed to mechanical injury, protect by pipes or other substantial guards. If guards are iron pipe, or other magnetic material, electrically connect conductors to both ends of the guard. Make connections as specified herein.
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M. Care shall be taken to ensure good ground continuity, in particular between the conduit system and equipment frames and enclosures. Where necessary, jumper wires shall be installed.
N. All grounding type receptacles shall be grounded to the outlet boxes with a No. 12 XHHW green conductor connected to the ground terminal of the receptacle and fastened to the outlet box by means of a grounding screw.
3.02 INSPECTION AND TESTING
A. Inspect the grounding and bonding system conductors and connections for tightness and proper installation.
B. Use Biddle Direct Reading Earth Resistance Tester or equivalent test instrument to measure resistance to ground of the system. Perform testing in accordance with test instrument manufacturer's recommendations using the fall-of-potential method. Notify the Engineer in writing at least two weeks prior to scheduling any testing. Provide certified calibration sheets including dates for all equipment to be used for testing with notice of scheduled testing. Calibration sheets shall also indicate that the units have been calibrated within six months of the testing date.
C. All test equipment shall be provided under this Section and approved by the Engineer.
D. Resistance to ground testing shall be performed during dry season. Submit test results in the form of a graph showing the number of points measured (12 minimum) and the numerical resistance to ground.
E. Testing shall be performed before energizing the distribution system.
F. A separate test shall be conducted for each building or system.
G. Dry season resistance of the system at each testing location shall not exceed five ohms. If such resistance cannot be obtained with the system, provide additional grounding, as directed by the Engineer, at no additional cost to the Owner.
END OF SECTION
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