TABLE OF CONTENTS
VOLUME 1 OF 3
Page Bidding Documents Notice Inviting Bids ...... A-1 Instructions to Bidders ...... B-1 Bid ...... C-1 Bid Bond ...... D-1 Information Required of Bidder ...... E-1
Contract Documents Agreement ...... F-1 Performance Bond ...... G-1 Payment Bond ...... H-1 Notice of Award ...... I-1 Notice to Proceed ...... J-1 Payment Application and Certificate ...... K-1 Change Order ...... L-1 Contractor's Certificate of Substantial Completion ...... M-1 Contractor's Certificate of Final Completion ...... N-1 Consent of Surety for Final Payment ...... O-1 Affidavit of Payment ...... P-1 Purchase Orders Assignment (not used) Contractor’s Current Business License ...... R-1 Certification of Bidder’s Experience and Qualifications ...... S-1 Resumes of Key Personnel ...... T-1 Approach to Project ...... U-1
GENERAL CONDITIONS OF THE CONTRACT
Article 1 Definitions ...... 1-1 2 Preliminary Matters ...... 2-1 3 Contract Documents: Intent, Amending, Reuse ...... 3-1 4 Availability of Land; Physical Conditions: Reference Points...... 4-1 5 Bonds and Insurance ...... 5-1 6 Contractor's Responsibilities ...... 6-1 7 Other Work ...... 7-1 8 Owner's Responsibilities ...... 8-1 9 Engineer's Status During Construction ...... 9-1 10 Changes in the Work ...... 10-1 11 Change of Contract Price ...... 11-1 12 Change of Contract Time ...... 12-1 13 Warranty and Guarantee; Tests and Inspections; Correction, Removal, Or Acceptance of Defective Work ...... 13-1 14 Payments to Contractor, Liquidated Damages and Completion ...... 14-1
BC&A TABLE OF CONTENTS JVWCD PAGE 00020-1 CENTRAL PIPELINE PROJECT TABLE OF CONTENTS (continued)
GENERAL CONDITIONS OF THE CONTRACT
Page Bidding Documents 15 Suspension of Work and Termination ...... 15-1 16 Miscellaneous ...... 16-1
SUPPLEMENTAL GENERAL CONDITIONS
6 Contractor’s Responsibilities ...... 6-1 17 General ...... 17-1 18 Amounts of Actual Damages, Award Incentives, and Bonds and Insurance ...... 18-1 19 Physical Conditions and Weather Delays ...... 19-1 20 Subcontract Limitations ...... 20-1 21 Miscellaneous ...... 21-1 22 Warranty Period ...... 22-1
TECHNICAL SPECIFICATIONS
DIVISION 1 – GENERAL REQUIREMENTS 01010 Summary of Work...... 01010-1 – 01010-5 01040 Coordination ...... 01040-1 – 01040-3 01070 Abbreviations of Institutions ...... 01070-1 – 01070-3 01090 Reference Standards ...... 01090-1 – 01090-2 01300 Contractor Submittals ...... 01300-1 – 01300-10 01301 Schedule of Values ...... 01301-1 – 01301-3 01302 Safety ...... 01302-1 – 01302-3 01311 CPM Construction Schedule ...... 01311-1 – 01311-8 01313 Construction and Schedule Constraints ...... 01313-1 – 01313-2 01335 Site Conditions Survey ...... 01335-1 – 01335-2 01400 Quality Assurance/Quality Control ...... 01400-1 – 01400-10 01450 Permits ...... 01450-1 – 01450-4 01505 Mobilization ...... 01505-1 – 01505-2 01506 Traffic Control ...... 01506-1 – 01506-9 01510 Temporary Utilities ...... 01510-1 – 01510-3 01515 Rights-of-Way ...... 01515-1 – 01515-1 01530 Protection and Restoration of Existing Facilities ...... 01530-1 – 01530-6 01550 Site Access and Storage ...... 01550-1 – 01550-3 01560 Temporary Environmental Controls ...... 01560-1 – 01560-4 01580 Project Sign ...... 01580-1 – 01580-2 01600 Products, Materials, Equipment and Substitutions ...... 01600-1 – 01600-4 01612 Seismic Design Criteria ...... 01612-1 – 01612-2 01614 Wind Design Criteria ...... 01614-1 – 01614-2
BC&A TABLE OF CONTENTS JVWCD PAGE 00020-2 CENTRAL PIPELINE PROJECT TABLE OF CONTENTS (continued)
Page
01660 Equipment Testing and Startup ...... 01660-1 – 01660-4 01700 Project Closeout ...... 01700-1 – 01700-4
DIVISION 2 – SITEWORK 02100 Site Preparation ...... 02100-1 – 02100-4 02200 Earthwork ...... 02200-1 – 02200-17 02216 Dewatering ...... 02216-1 – 02216-3 02273 Riprap ...... 02273-1 – 02273-5 02274 Geotextiles ...... 00274-1 – 02274-7 02277 Grouted Riprap ...... 02277-1 – 02277-3 02460 A.C. Pavement and Base ...... 02460-1 – 02460-11 02570 Steel Pipe ...... 02570-1 – 02570-22 02572 Steel Pipe Fabricated Specials ...... 02572-1 – 02572-6 02590 High Density Polyethylene Pipe ...... 02590-1 – 02590-6 02615 Disposal of Water ...... 02615-1 – 02615-2 02643 Water Pipeline Testing and Disinfection ...... 02643-1 – 02643-5 02830 Chain Link Fencing and Gates ...... 02830-1 – 02830-8 02900 Landscaping ...... 02900-1 – 02900-9
DIVISION 3 – CONCRETE 03100 Concrete Formwork ...... 03100-1 – 03100-6 03200 Reinforcement Steel ...... 03200-1 – 03200-7 03300 Cast-in-Place Concrete ...... 03300-1 – 03300-27 03315 Grout ...... 03315-1 – 03315-10
DIVISION 4 – MASONRY 04100 Mortar and Grout ...... 04100-1 – 04100-4 04800 Reinforced Masonry Assemblies ...... 04800-1 – 04800-11 04900 Masonry Cleaning ...... 04900-1 – 04900-5
DIVISION 5 – METALS 05500 Metal Fabrications ...... 05500-1 – 05500-15 05521 Pipe and Tubing Railings ...... 05521-1 – 05521-8
DIVISION 6 – WOOD AND PLASTICS 06105 Miscellaneous Carpentry ...... 06105-1 – 06105-8 06160 Sheathing ...... 06160-1 – 06160-3 06170 Shop Fabricated Wood Trusses ...... 06170-1 – 01670-8 06610 Fiberglass Reinfored Plastic Fabrications ...... 06610-1 – 06610-7
VOLUME 2 OF 3
DIVISION 7 – THERMAL AND MOISTURE PROTECTION 07142 Fluid-Applied Rubberized Asphalt Waterproofing ...... 07142-1 – 07142-4 07190 Water Repellents ...... 07190-1 – 07190-5
BC&A TABLE OF CONTENTS JVWCD PAGE 00020-3 CENTRAL PIPELINE PROJECT TABLE OF CONTENTS (continued)
Page
07200 Rigid Insulation ...... 07200-1 – 07200-2 07210 Building Insulation ...... 07210-1 – 07210-7 07410 Manufactured Fascia and Soffit Panels ...... 07410-1 – 07410-4 07411 Metal Roof Panels ...... 07411-1 – 07411-15 07620 Sheet Metal Flashing and Trim ...... 07620-1 – 07620-12 07720 Roof Accessories ...... 07720-1 – 07720-3 07841 Through-Penetration Firestop Systems ...... 07841-1 – 07841-8 07900 Joint Sealants ...... 07900-1 – 07900-7
DIVISION 8 – DOORS AND WINDOWS 08110 Steel Doors and Frames ...... 08110-1 – 08110-7 08220 Fiberglass-Reinforced Plastic Doors and Frames ...... 08220-1 – 08220-6 08311 Access Doors and Frames ...... 08311-1 – 08311-6 08331 Overhead Coiling Doors ...... 08331-1 – 08331-7 08711 Door Hardware ...... 08711-1 – 08711-16
DIVISION 9 – FINISHES 09900 Painting ...... 09900-1 – 009900-25 09910 Pipeline Coatings and Linings ...... 09910-1 – 09910-29
DIVISION 10 – SPECIALTIES 10425 Signs ...... 10425-1 – 10425-9
DIVISION 11 – EQUIPMENT 11000 Equipment General Provisions ...... 11000-1 – 11000-12 11100 Pumps, General ...... 11100-1 – 11100-8 11111 ANSI Horizontal end Suction Magnetic Drive Pumps ...... 11111-1 – 11111-6 11258 Chemical Feeding Equipment, General ...... 11258-1 – 11258-6
DIVISION 13 – SPECIAL CONSTRUCTION 13115 Impressed Current Cathodic Protection ...... 13115-1 – 13115-31 13675 Polyethylene Tanks ...... 13675-1 – 13675-10
DIVISION 15 – MECHANICAL 15000 Piping, General ...... 15000-1 – 15000-7 15005 Piping Identification System ...... 15005-1 – 15005-3 15006 Pipe Supports ...... 15006-1 – 15006-7 15007 Non-Metallic Pipe Support System ...... 15007-1 – 15007-4 15010 Mill Piping – Exposed and Buried ...... 15010-1 – 15010-7 15052 Common Work Results for Plumbing and HVAC ...... 15052-1 – 15052-5 15065 CPVC Pressure Pipe ...... 15065-1 – 15065-3 15071 Seismic Controls for Plumbing and HVAC ...... 15071-1 – 15071-6 15075 Meters, General ...... 15075-1 – 15075-5 15076 Identification for Plumbing and HVAC Piping and Equipment ...... 15076-1 – 15076-3
BC&A TABLE OF CONTENTS JVWCD PAGE 00020-4 CENTRAL PIPELINE PROJECT TABLE OF CONTENTS (continued)
Page
15080 HVAC and Plumbing Insulation ...... 15080-1 – 15080-4 15180 Strainers ...... 15180-1 – 15180-3 15194 Natural Gas Piping ...... 15194-1 – 15194-8 15200 Valves, General ...... 15200-1 – 15200-6 15201 Valve and Gate Actuators ...... 15201-1 – 15201-7 15202 Butterfly Valves ...... 15202-1 – 15202-8 15203 Check Valves ...... 15203-1 – 15203-2 15204 Ball Valves ...... 15204-1 – 15204-2 15206 Gate Valves ...... 15206-1 – 15206-2 15207 Plug Valves ...... 15207-1 – 15207-2 15215 Pressure Relief Vales ...... 15215-1 – 15215-3 15218 Pressure Reducing Valves ...... 15218-1 – 15218-3 15235 Fire Hydrants ...... 15235-1 – 15325-2 15420 Emergency Eye/Face Wash and Shower Equipment ...... 15420-1 – 15420-4 15485 Electric Water Heaters ...... 15485-1 – 15485-5 15543 Fuel-Fired Unit Heaters ...... 15543-1 – 15543-4 15785 Air-to-Air Energy Recovery Equipment ...... 15785-1 – 15785-4 15815 Metal Ducts ...... 15815-1 – 15815-10 15820 Duct Accessories...... 15820-1 – 15820-6 15838 Power Ventilators ...... 15838-1 – 15838-6 15855 Diffusers, Registers, and Grilles ...... 15855-1 – 15855-2 15950 Testing, Adjusting, and Balancing ...... 15950-1 – 15950-5
DIVISION 16 – ELECTRICAL 16050 Electrical General Provisions ...... 16050-1 – 16050-23 16222 Motors 250HP and Less ...... 16222-1 – 16222-10 16422 Motor Starters ...... 16422-1 – 16422-11 16476 Low Voltage Circuit Breakers ...... 16476-1 – 16476-6 16500 Lighting ...... 16500-1 – 16500-3
DIVISION 17 – INSTRUMENTATION 17050 Process Control and Instrumentation Systems General ...... 17050-1 – 17050-8 17421 Fiber Optic Cable Subsystem ...... 17421-1 – 17421-9
VOLUME 3 OF 3
DRAWINGS
BC&A TABLE OF CONTENTS JVWCD PAGE 00020-5 CENTRAL PIPELINE PROJECT
DIVISION 7 THERMAL AND MOISTURE PROTECTION
SECTION 07142 FLUID-APPLIED RUBBERIZED ASHPALT WATERPROOFING
GENERAL
1.1 SUMMARY
Section includes.
1. Waterproofing system applied to below-grade concrete walls, roof slabs, and footings and includes high solids, polymer-modified asphalt emulsion.
1.2 RELATED SECTIONS
Section 07900 – Joint Sealants.
1.3 REFERENCES
ASTM International (ASTM) standards, most recent editions:
ASTM D4263 Standard Test Method for Indicating Moisture in Concrete by the Plastic Sheet Method
1.4 QUALITY ASSURANCE
Qualifications:
1. Installer qualifications: A firm that is approved or licensed by the manufacturer of the material for installation of waterproofing as required for this Work and is eligible to receive special warranties specified.
Source limitation: Obtain waterproofing materials from a single manufacturer.
1.5 SUBMITTALS
Comply with Section 01300.
Product Data
1. Letter of certification that products submitted meet requirements of standards referenced. 2. Manufacturer's written instructions for evaluating, preparing, and treating substrate. 3. Technical data including tested physical and performance properties of the waterproofing.
BC&A FLUID-APPLIED RUBBERIZED JVWCD ASPHALT WATERPROOFING CENTRAL PIPELINE PROJECT PAGE 07142-1 Shop drawings
1. Show location and extent of waterproofing.
Sample special warranty.
1.6 DELIVERY, STORAGE, AND HANDLING
Deliver products to site, store and protect products under provisions of Section 01600.
Deliver material in manufacturer's original unopened containers with labels intact. Labels shall indicate contents and expiration date of material.
Store liquid materials in their original undamaged containers in a clean, dry, protected location and within the temperature range required by the waterproofing manufacturer.
Remove and replace liquid materials that cannot be applied within their stated shelf life.
1.7 ENVIRONMENTAL REQUIREMENTS
Schedule Work to be performed when temperature and humidity are as recommended by the waterproofing manufacturer during and after installation until products are fully cured.
Do not apply waterproofing in snow, rain, fog, or mist.
Maintain adequate ventilation during application and curing of waterproofing materials.
1.8 WARRANTY
Special warranty: Manufacturer’s standard form in which manufacturer agrees to repair or replace waterproofing that does not comply with requirements or that fail to remain watertight within specified period.
1. Waterproofing work shall be free of defects for a period of 2 years from date of final acceptance. 2. Failure of watertightness constitutes defect. 3. Remove any defective work and/or materials and replace with new materials. 4. Warranty must be signed jointly by installer and waterproofing manufacturer.
PRODUCTS
2.1 MANUFACTURERS
Subject to compliance with the Contract Documents, the following Manufacturers are acceptable:
1. Asphalt emulsion waterproofing membrane. a. Epro Services, Inc. b. ENGINEER approved equal.
BC&A FLUID-APPLIED RUBBERIZED JVWCD ASPHALT WATERPROOFING CENTRAL PIPELINE PROJECT PAGE 07142-2 2.2 MATERIALS
Asphalt emulsion waterproofing membrane.
1. High-solids, polymer modified asphalt emulsion. Provide Ecobase II by Epro Services, Inc. or ENGINEER approved equal.
EXECUTION
3.1 EXAMINATION
Examine substrates, areas, and conditions, with installer present, for compliance with requirements for installation tolerances and other conditions affecting performance of the Work.
1. Verify that concrete has cured and aged for minimum time period recommended by waterproofing manufacturer. 2. Verify that substrate is visibly dry and free of moisture. Test for capillary moisture by plastic sheet method according to ASTM D4263.
3.2 PREPARATION
Clean and prepare substrates according to manufacturer's written instructions. Provide clean, dust-free, and dry substrate for waterproofing application.
Mask off adjoining surfaces not receiving waterproofing to prevent spillage and overspray affecting other construction.
Close off penetrations to prevent spillage and migration of waterproofing fluids.
Remove grease, oil, form-release agents, paints, curing compounds, and other penetrating contaminants or film-forming coatings from concrete.
Remove fins, ridges, and other projections and fill honeycomb, aggregate pockets, and other voids.
3.3 JOINTS, CRACKS, AND TERMINATIONS
Prepare and treat substrates to receive waterproofing membrane, including joints and cracks, deck drains, corners, and penetrations according to manufacturer’s written instructions.
3.4 MEMBRANE APPLICATION
Apply using appropriate equipment and nozzles, per manufacturer’s recommendations. Start application with manufacturer's authorized representative present.
Membrane: Spray-apply asphalt emulsion membrane to substrates and adjoining surfaces indicated. Apply a total thickness of 40 mils (coverage rate of approximately 30 square feet per gallon).
BC&A FLUID-APPLIED RUBBERIZED JVWCD ASPHALT WATERPROOFING CENTRAL PIPELINE PROJECT PAGE 07142-3 Apply waterproofing over prepared joints and up wall terminations and vertical surfaces to heights indicated or required by manufacturer.
Allow product to cure prior to backfilling. When buried surfaces that have been waterproofed are not backfilled within two days of membrane application, membrane shall be coated with whitewash. Any formula for mixing the whitewash may be used which is not detrimental to the membrane and produces a uniformly coated white surface which remains until backfill is placed.
3.5 FIELD QUALITY CONTROL
Engage a full-time site representative qualified by the waterproofing membrane manufacturer to inspect substrate conditions, surface preparation, and application of the membrane.
1. Furnish field-control reports to ENGINEER daily.
3.6 PROTECTION
Protect waterproofing from damage and wear during remainder of construction period.
END OF SECTION
BC&A FLUID-APPLIED RUBBERIZED JVWCD ASPHALT WATERPROOFING CENTRAL PIPELINE PROJECT PAGE 07142-4 SECTION 07190 WATER REPELLENTS
PART 1 - GENERAL
1.1 SUMMARY
A. Section includes exterior water repellent coatings for concrete unit masonry (unpainted and unglazed). 1. Silicone Water Repellents
B. Related Sections 1. Section 04800 – Reinforced Masonry Assemblies
1.2 REFERENCES
A. ASTM International (ASTM) standards, most recent editions:
ASTM D2369 Standard Test Method for Volatile Content of Coatings
ASTM D3278 Standard Test Methods for Flash Point of Liquids by Small Scale Closed-Cup Apparatus
1.3 SUBMITTALS
A. Comply with Section 01300.
B. Product Data: Manufacturer’s technical data to include the following: 1. Detailed installation instructions. 2. Protection and cleaning instructions. 3. Certified test reports indicating compliance with requirements specified herein. 4. Data substantiating that materials are recommended by manufacturer for applications included in this Work.
C. Samples: Provide samples of each substrate indicated to receive water repellent, 8 inches square, with specified repellent treatment applied to half of the sample.
D. Applicator Certificates: Provide letter on Manufacturer’s letterhead certifying that the applicator is approved to apply products supplied.
E. Test and Evaluation Reports: Results of rilem tube testing and application rates determined therefrom.
F. Warranty Documentation.
1.4 QUALITY ASSURANCE
A. Qualifications 1. Manufacturers: Use products from manufacturer with not less than 5 years’ experience.
BC&A JVWCD WATER REPELLENTS CENTRAL PIPELINE PROJECT PAGE 07190 - 1 2. Applicators: Firm experienced in application of systems similar in complexity to those required for this Project, plus the following: a. Acceptable to, or licensed by manufacturer. b. Not less than 3 years’ experience with systems. c. Successfully completed not less than 5 comparable scale projects using the same system.
B. Test Area: Test a minimum 4 feet by 4 feet area on each type of masonry surface in the Work. 1. Use the manufacturer’s application instructions. 2. Let test area protective treatment cure before inspection. 3. Perform rilem tube testing to determine coverage rate to be used. 4. Obtain ENGINEER’s approval of test areas and resulting application rates to be used before proceeding with full scale application.
1.5 DELIVERY, STORAGE, AND HANDLING
A. Comply with Section 01600.
B. Packaging and Shipping: Deliver products in original unopened packaging with legible manufacturer’s identification.
C. Storage and Handling Requirements: Comply with manufacturer’s instructions.
1.6 SITE CONDITIONS
A. Maintain surface and ambient temperature above 40 degrees F during, and 24 hours after application.
B. Do not proceed with application on materials where ice and snow exist.
C. Do not proceed with application if surface temperature exceeds 100 degrees F.
D. Do not proceed with application when windy conditions exist that may cause water repellent to be blown onto vegetation or surfaces not intended to be coated.
E. Do not proceed with the application of materials in rainy conditions or when rain is anticipated within 6 hours after application.
1.7 WARRANTY
A. General Warranty: The special warranty specified in this Article shall not deprive the OWNER of other rights the OWNER may have under other provisions of the Contract Documents and shall be in addition to, and run concurrent with, other warranties made by the CONTRACTOR under requirements of the Contract Documents.
B. Special Warranty: Submit a written warranty, executed by the applicator and water repellent manufacturer, covering materials and labor, agreeing to repair or replace materials that fail to provide water repellency within the specified warranty period. Warranty does not include deterioration or failure of coating due to unusual weather
BC&A JVWCD WATER REPELLENTS CENTRAL PIPELINE PROJECT PAGE 07190 - 2 phenomena, failure of prepared and treated substrate, formation of new joints and cracks in excess of 1/16 inch (1.5 mm) wide, fire, vandalism, or abuse by maintenance equipment.
C. Warranty Period: 5 years from date of Substantial Completion.
D. Retreat all defective areas as identified by the ENGINEER.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. Subject to compliance with the Contract Documents, the following Manufacturers are acceptable: 1. Silicone Water Repellent: a. Weather Seal Blok-Guard & Graffiti Control; ProSoCo, Inc. b. ENGINEER approved equal
2.2 MATERIALS
A. Masonry: Refer to Section 04800 – Reinforced Masonry Assemblies.
B. Silicone Sealer: 1. Film-forming, polymerized, silicone-resin water repellent for dense substrates. 2. Solvent based solution containing not less than 8% solids per ASTM D2369. 3. Flash Point: 100 degrees F per ASTM D3278. 4. Freeze Point: Lower than -22 degrees F.
PART 3 - EXECUTION
3.1 EXAMINATION
A. Verification of Conditions: Examine system components, substrate, and conditions where water repellents are to be installed. If unsatisfactory conditions exist, notify ENGINEER in writing of unsatisfactory conditions and do not begin this Work until such conditions have been corrected.
B. Commencing installation of this Work constitutes acceptance of conditions.
3.2 PREPARATION
A. Clean substrate of substances that might interfere with penetration or performance of water repellents.
B. Test for moisture content, according to repellent manufacturer's written instructions, to ensure surface is sufficiently dry.
C. Test for pH level, according to water repellent manufacturer's written instructions, to ensure chemical bond to silicate minerals.
BC&A JVWCD WATER REPELLENTS CENTRAL PIPELINE PROJECT PAGE 07190 - 3 D. Protect adjoining work, including sealant bond surfaces, from spillage or blow over of water repellent. Cover adjoining and nearby surfaces of aluminum and glass if there is the possibility of water repellent being deposited on surfaces. Cover live plants and grass.
E. Coordination with Sealants: Do not apply water repellent until sealants for joints adjacent to surfaces receiving water repellent treatment have been installed and cured.
3.3 APPLICATION
A. Apply product as supplied by the manufacturer without dilution or alteration unless dilution is specifically included in the manufacturer’s instructions. 1. Apply using low pressure spray equipment (<50 psi). 2. Saturate the surface in a “wet-on-wet” application from the bottom up, creating a 6 inch to 8 inch rundown below the spray contact point. 3. Avoid excessive overlapping. 4. Allow the application to penetrate the masonry surface and immediately brush out runs and drips to prevent build-up.
B. Brush apply water repellent only at locations where overspray would affect adjacent materials and where not practicable for spray application.
C. Apply a minimum of 2 coats at rate determined by the manufacturer as a result of the test panel evaluations. Comply with manufacturer’s written instructions on limitations on drying time between coats.
3.4 RESTORATION
A. Repair, restore, or replace to the satisfaction of ENGINEER, any materials, landscaping, and nonmasonry surfaces damaged by exposure to water repellents.
3.5 FIELD QUALITY CONTROL
A. Manufacturer Services: Provide services of a manufacturer-authorized technical service representative to approve the substrate before application and to instruct the applicator on the application rates and methods.
3.6 CLEANING
A. While Work Progresses: Clean spillage and overspray from adjacent surfaces using materials and methods as recommended by water repellent manufacturer.
B. Remove and dispose of all materials used to protect surrounding areas and nonmasonry surfaces, following completion of the work of this Section.
C. Clean site of all unused water repellents, residues, rinse water, wastes, and effluents in accordance with environmental regulations.
BC&A JVWCD WATER REPELLENTS CENTRAL PIPELINE PROJECT PAGE 07190 - 4 3.7 EXTERIOR SCHEDULE
A. Provide water repellent to exterior masonry surfaces of the following structures: 1. Fluoride Building
END OF SECTION
BC&A JVWCD WATER REPELLENTS CENTRAL PIPELINE PROJECT PAGE 07190 - 5
SECTION 07200 RIGID INSULATION
PART 1 – GENERAL
1.1 REQUIREMENTS 1. Provide rigid insulation on all buried concrete vault roof and walls. Wall insulation shall extend 4-foot below finishing grade elevation.
1.2 REFERENCES
A. The following is a list of standards which may be referenced in this section:
1. American Society for Testing and Materials (ASTM): a. C578, Standard Specification for Rigid, Cellular Polystyrene Thermal Insulation.
1.3 SUBMITTALS
A. Submit product data and samples including adhesive and fasteners.
1.4 MATERIAL STORAGE
A. Store off ground and keep dry at all times. Protect against weather condensation and damage.
PART 2 – PRODUCTS
2.1 RIGID INSULATION FOR VAULTS (BLUE BOARD)
A. Rigid Insulation: ASTM C578, Type IV (25 psi), extruded polystyrene. Use 2-inch thick, CFC-blown, extruded polystyrene with an R-value of 5 hour foot squared degree F/BTU per inch, blue in color. Use STYROFOAM brand Square Edge insulation as manufactured by Dow Chemical.
1. Insulation shall be manufactured with a blowing agent which provides at least 90% reduction in ozone depletion potential compared to standard CFC blowing agents. Other insulations are not acceptable. 2. Insulation shall be new, free from defects, and of uniform color. 3. Insulation shall have a limited thermal warranty stating that the R-value will not deviate more than 10% from its published value for a period of 15 years from the manufacturing date printed on the insulation boards.
2.2 ADHESIVE AND MECHANICAL ANCHORS
A. Adhesive shall be recommended by insulation manufacturer for use with polystyrene foam. Adhesive shall be formulated specifically to bond insulation to steel and concrete surfaces.
BC&A RIGID INSULATION JVWCD PAGE 07200-1 CENTRAL PIPELINE PROJECT B. In addition to adhesive, use mechanical fasteners to mechanically and permanently bind polystyrene insulation to the concrete and other surfaces. Mechanical anchors shall be Hilti IDP Poly Insulation Anchors, or approved equal.
PART 3 – EXECUTION
3.1 INSTALLATION
A. Install the insulation on the vault wall, roof slab, and access hatch with lemon-sized gobs of compatible adhesive and mechanical fasteners.
Mechanical anchors shall be placed at each corner of the board insulation, and a minimum of two rows of three anchors shall be installed per standard sheet. Run the insulation to the line shown on the plans. Keep all joints and abutments tight. Do not apply adhesive to insulation that will deleteriously affect it in any way.
B. Follow manufacturer’s instructions on storing and handling the insulation.
1. Shield the insulation with an opaque, light-colored tarp if it will be stored in direct sunlight. 2. Protect insulation from open flame and from heat sources over 165 degrees F. 3. Avoid contact with petroleum-based solvents or with molten asphalt or tar.
C. Butt joints tightly together.
3.2 CLEANUP AND PROTECTION
A. Remove from site all containers, wrappings, and scrap insulation material. Leave floors broom clean.
END OF SECTION
BC&A RIGID INSULATION JVWCD PAGE 07200-2 CENTRAL PIPELINE PROJECT SECTION 07210 BUILDING INSULATION
PART 1 – GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section includes the following:
1. Foundation wall insulation (supporting backfill). 2. Concealed building insulation. 3. Radiant barriers. 4. Safing insulation.
B. Related Sections: The following Sections contain requirements that relate to this Section:
1. Division 1 Section "LEED Requirements" for LEED certification targets, related LEED requirements, recycled content minima, other LEED criteria and constraints. 2. Information attached for reference, including LEED Checklist for Project building(s), indicating which LEED credits are targeted for attainment. 3. LEED reference documents, not attached but available for use, including the “LEED- New Construction v.2.2 Rating System,” explaining requirements for each prerequisite and credit, and the “LEED-New Construction v2.2 Reference Guide,” detailing requirements and documentation options for application for each prerequisite and credit. 4. Division 4 Section "Unit Masonry" for insulation installed in and masonry cells. 5. Division 7 Section "Metal Roof Panels" for insulation specified as part of roofing construction. 6. Division 9 Section indicated below for insulation installed as part of metal-framed wall and partition assemblies: a. "Gypsum Board Assemblies."
1.3 SUBMITTALS
A. General: Submit each item in this Article according to the Conditions of the Contract and Division 1 Specification Sections.
B. Product Data for each type of insulation product specified.
C. Product test reports from and based on tests performed by a qualified independent testing agency evidencing compliance of insulation products with specified requirements including those for thermal resistance, fire-test-response characteristics, water-vapor transmission, water absorption, and other properties, based on comprehensive testing of current products.
BC&A BUILDING INSULATION JVWCD PAGE 07210-1 CENTRAL PIPELINE PROJECT
D. LEED Submittals:
1. Product Data for Credit MR 4.1 and Credit MR 4.2: For products having recycled content, documentation indicating percentages by weight of postconsumer and preconsumer recycled content. Include statement indicating costs for each product having recycled content.
1.4 QUALITY ASSURANCE
A. Single-Source Responsibility for Insulation Products: Obtain each type of building insulation from a single source with resources to provide products complying with requirements indicated without delaying the Work.
B. Fire-Test-Response Characteristics: Provide insulation and related materials with the fire-test-response characteristics indicated on Drawings or specified elsewhere in this Section as determined by testing identical products per test method indicated below by UL or another testing and inspecting agency acceptable to authorities having jurisdiction. Identify materials with appropriate markings of applicable testing and inspecting agency.
1. Surface-Burning Characteristics: ASTM E 84. 2. Fire-Resistance Ratings: ASTM E 119. 3. Combustion Characteristics: ASTM E 136.
1.5 DELIVERY, STORAGE, AND HANDLING
A. Protect insulation materials from physical damage and from deterioration by moisture, soiling, and other sources. Store inside and in a dry location. Comply with manufacturer's written instructions for handling, storing, and protecting during installation.
B. Protect plastic insulation as follows:
1. Do not expose to sunlight, except to extent necessary for period of installation and concealment. 2. Protect against ignition at all times. Do not deliver plastic insulating materials to Project site before installation time. 3. Complete installation and concealment of plastic materials as rapidly as possible in each area of construction.
PART 2 – PRODUCTS
2.1 MANUFACTURERS
A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering insulation products that may be incorporated in the Work include, but are not limited to, the following:
1. Extruded-Polystyrene Board Insulation: a. Amoco Foam Products Company. b. DiversiFoam Products.
BC&A BUILDING INSULATION JVWCD PAGE 07210-2 CENTRAL PIPELINE PROJECT c. Dow Chemical Co. d. UC Industries, Inc.; Owens-Corning Co. 2. Glass-Fiber Insulation: a. CertainTeed Corporation. b. Knauf Fiber Glass GmbH. c. Owens-Corning Fiberglas Corporation. d. Johns Manville Corporation.
2.2 INSULATING MATERIALS
A. General: Provide insulating materials that comply with requirements and with referenced standards.
1. Preformed Units: Sizes to fit applications indicated; selected from manufacturer's standard thicknesses, widths, and lengths.
B. Extruded-Polystyrene Board Insulation: Rigid, cellular polystyrene thermal insulation formed from polystyrene base resin by an extrusion process using hydrochlorofluorocarbons as blowing agent to comply with ASTM C 578 for type and with other requirements indicated below:
1. Type IV, 1.60-lb/cu. ft. minimum density, unless otherwise indicated. 2. Surface-Burning Characteristics: Maximum flame-spread and smoke-developed indices of 75 and 450, respectively. 3. Recycled Content: Not less than 50 percent blend of postconsumer and recovered polystyrene resins.
C. Unfaced Mineral-Fiber Blanket Insulation: Thermal insulation combining mineral fibers of type described below with thermosetting resins to comply with ASTM C 665, Type I (blankets without membrane facing).
1. Mineral-Fiber Type: Fibers manufactured from glass. 2. Surface-Burning Characteristics: Maximum flame-spread and smoke-developed indices of 25 and 50, respectively.
D. Faced Mineral-Fiber Blanket Insulation: ASTM C 665, Type III (blankets with reflective membrane facing), Class A (membrane-faced surface with a flame spread of 25 or less); Category 1 (membrane is a vapor barrier), faced with foil-scrim-kraft, foil-scrim, or foil-scrim-polyethylene vapor-retarder membrane on one face; consisting of fibers manufactured from glass.
E. Sound Attenuation Blankets: ASTM C 665, Type I; semi-rigid mineral fiber blanket without membrane, Class 25 flame-spread. Furnish in 2-3/4", 4" and 6" thicknesses. Provide minimum thickness as required to achieve a minimum 50 STC in all walls.
2.3 SAFING INSULATION AND ACCESSORIES
A. Slag-Wool-Fiber Board Safing Insulation: Semirigid boards designed for use as fire stop at openings between edge of slab and exterior wall panels, produced by combining slag-wool fibers with thermosetting resin binders to comply with ASTM C 612, Type IA and IB; nominal
BC&A BUILDING INSULATION JVWCD PAGE 07210-3 CENTRAL PIPELINE PROJECT density of 4 lb/cu. ft.; passing ASTM E 136 for combustion characteristics; thermal resistivity of 4 deg F x h x sq. ft./Btu x in. at 75 deg F.
B. Calking Compound: Material approved by manufacturer of safing insulation for sealing joint between foil backing of safing insulation and edge of concrete floor slab against penetration of smoke.
C. Safing Clips: Galvanized steel safing clips approved by manufacturer of safing insulation for holding safing insulation in place.
2.4 VAPOR RETARDERS
A. Reinforced-Polyethylene Vapor Retarders: 2 outer layers of polyethylene film laminated to an inner reinforcing layer consisting of either nylon cord or polyester scrim and weighing not less than 25 lb/1000 sq. ft., with maximum permeance rating of 0.0507 perm.
B. Vapor-Retarder Tape: Pressure-sensitive tape of type recommended by vapor retarder manufacturer for sealing joints and penetrations in vapor retarder.
C. Available Products: Subject to compliance with requirements, products that may be incorporated into the Work include, but are not limited to, the following:
1. Reinforced-Polyethylene Vapor Retarders: a. DURA-SKRIM 6WW; Raven Industries, Inc. b. Griffolyn T-65; Reef Industries, Inc., Griffolyn Div.
2.5 AUXILIARY INSULATING MATERIALS
A. Adhesive for Bonding Insulation: Product with demonstrated capability to bond insulation securely to substrates indicated without damaging insulation and substrates.
2.6 INSULATION FASTENERS
A. Adhesively Attached, Spindle-Type Anchors: Plate welded to projecting spindle; capable of holding insulation, of thickness indicated, securely in position indicated with self-locking washer in place; and complying with the following requirements:
1. Plate: Perforated galvanized carbon-steel sheet, 0.030 inch thick by 2 inches square. 2. Spindle: Copper-coated low carbon steel, fully annealed, 0.105 inches in diameter, length to suit depth of insulation indicated.
B. Insulation-Retaining Washers: Self-locking washers formed from 0.016-inch- thick galvanized steel sheet, with beveled edge for increased stiffness, sized as required to hold insulation securely in place, but not less than 1-1/2 inches square or in diameter.
1. Where spindles will be exposed to human contact after installation, protect ends with capped self-locking washers incorporating a spring steel insert to ensure permanent retention of cap.
BC&A BUILDING INSULATION JVWCD PAGE 07210-4 CENTRAL PIPELINE PROJECT C. Anchor Adhesive: Product with demonstrated capability to bond insulation anchors securely to substrates indicated without damaging insulation, fasteners, and substrates.
D. Available Products: Subject to compliance with requirements, products that may be incorporated into the Work include, but are not limited to, the following:
1. Adhesively Attached, Spindle-Type Anchors: a. TACTOO Insul-Hangers; AGM Industries, Inc. b. Spindle Type Gemco Hangers; Gemco. 2. Anchor Adhesives: a. TACTOO Adhesive; AGM Industries, Inc. b. Tuff Bond Hanger Adhesive; Gemco.
PART 3 – EXECUTION
3.1 EXAMINATION
A. Examine substrates and conditions, with Installer present, for compliance with requirements of Sections in which substrates and related work are specified and to determine if other conditions affecting performance of insulation are satisfactory. Do not proceed with installation until unsatisfactory conditions have been corrected.
3.2 PREPARATION
A. Clean substrates of substances harmful to insulations or vapor retarders, including removing projections capable of puncturing vapor retarders or that interfere with insulation attachment.
3.3 INSTALLATION, GENERAL
A. Comply with insulation manufacturer's written instructions applicable to products and application indicated.
B. Install insulation that is undamaged, dry, unsoiled, and has not been exposed at any time to ice and snow.
C. Extend insulation in thickness indicated to envelop entire area to be insulated. Cut and fit tightly around obstructions and fill voids with insulation. Remove projections that interfere with placement.
D. Apply single layer of insulation to produce thickness indicated, unless multiple layers are otherwise shown or required to make up total thickness.
3.4 INSTALLATION OF PERIMETER INSULATION
A. On vertical surfaces, set units in adhesive applied according to manufacturer's written instructions. Use adhesive recommended by insulation manufacturer.
B. Protect below-grade insulation on vertical surfaces from damage during backfilling by applying protection board. Set in adhesive according to written instructions of insulation manufacturer.
BC&A BUILDING INSULATION JVWCD PAGE 07210-5 CENTRAL PIPELINE PROJECT
3.5 INSTALLATION OF GENERAL BUILDING INSULATION
A. Apply insulation units to substrates by method indicated, complying with manufacturer's written instructions. If no specific method is indicated, bond units to substrate with adhesive or use mechanical anchorage to provide permanent placement and support of units.
B. Seal joints between closed-cell (nonbreathing) insulation units by applying adhesive, mastic, or sealant to edges of each unit to form a tight seal as units are shoved into place. Fill voids in completed installation with adhesive, mastic, or sealant as recommended by insulation manufacturer.
C. Set vapor-retarder-faced units with vapor retarder to warm side of construction, unless otherwise indicated. Do not obstruct ventilation spaces, except for firestopping.
1. Tape joints and ruptures in vapor retarder, and seal each continuous area of insulation to surrounding construction to ensure airtight installation.
D. Install mineral-fiber blankets in cavities formed by framing members according to the following requirements:
1. Use blanket widths and lengths that fill cavities formed by framing members. Where more than one length is required to fill cavity, provide lengths that will produce a snug fit between ends. 2. Place blankets in cavities formed by framing members to produce a friction fit between edges of insulation and adjoining framing members.
E. Stuff glass-fiber loose-fill insulation into miscellaneous voids and cavity spaces. Compact to approximately 40 percent of normal maximum volume equaling a density of approximately 2.5 lb/cu. ft.
3.6 INSTALLATION OF SAFING INSULATION
A. Install safing insulation to fill gap between edge of concrete floor slab and back of exterior spandrel panels on safing clips spaced as needed to support insulation, but not further apart than 24 inches o.c. Cut safing insulation wider than gap to be filled to ensure compression fit and seal joint between insulation and edge of slab with calking approved by safing insulation manufacturer for this purpose. Leave no voids in completed installation.
3.7 INSTALLATION OF VAPOR RETARDERS
A. General: Extend vapor retarder to extremities of areas to be protected from vapor transmission. Secure in place with adhesives or other anchorage system as indicated. Extend vapor retarder to cover miscellaneous voids in insulated substrates, including those filled with loose-fiber insulation.
B. Seal vertical joints in vapor retarders over framing by lapping not less than 2 wall studs. Fasten vapor retarders to framing at top, end, and bottom edges; at perimeter of wall openings; and at lap joints. Space fasteners 16 inches o.c.
BC&A BUILDING INSULATION JVWCD PAGE 07210-6 CENTRAL PIPELINE PROJECT C. Seal overlapping joints in vapor retarders with adhesives or vapor-retarder tape according to vapor retarder manufacturer's instructions. Seal butt joints and fastener penetrations with vapor-retarder tape. Locate all joints over framing members or other solid substrates.
D. Firmly attach vapor retarders to substrates with mechanical fasteners or adhesives as recommended by vapor retarder manufacturer.
E. Seal joints caused by pipes, conduits, electrical boxes, and similar items penetrating vapor retarders with vapor-retarder tape to create an airtight seal between penetrating objects and vapor retarder.
F. Repair any tears or punctures in vapor retarders immediately before concealment by other work. Cover with vapor-retarder tape or another layer of vapor retarder.
3.8 PROTECTION
A. General: Protect installed insulation and vapor retarders from damage due to harmful weather exposures, physical abuse, and other causes. Provide temporary coverings or enclosures where insulation is subject to abuse and cannot be concealed and protected by permanent construction immediately after installation.
END OF SECTION
BC&A BUILDING INSULATION JVWCD PAGE 07210-7 CENTRAL PIPELINE PROJECT
SECTION 07410 MANUFACTURED FASCIA AND SOFFIT PANELS
PART 1 – GENERAL
1.1 SUMMARY
A. Section includes manufactured fascia and soffit panels of the following types, and metal flashing and counter flashing match panel material and finish.
1. Vee-Panel (Berridge).
B. Related Documents: Drawings and general provisions of Contract, including General and Supplementary Conditions and Division 1 specifications Sections, apply to this section.
1.2 SYSTEM PERFORMANCE REQUIREMENTS
A. Provide certified test results by a recognized testing laboratory or agency in accordance with specified test methods for each system.
B. Water Penetration: Provide panel systems with no water penetration as defined in the test method when tested in accordance with ASTM E 331 at an inward static air pressure differential of not less than 6.24 psf and not more than 12.0 psf.
1.3 CONTRACTOR SUBMITTALS
A. Product data: Submit manufacturer's product specifications, standard details, certified product test results, installation instructions, and general recommendations, as applicable to materials and finishes for each component and for total panel system.
B. Samples: Submit in form of manufacturer's color charts or chips showing full range of colors, textures, and patterns available for roof and wall panels with factory-applied finishes.
1. Samples shall be of actual coated material.
C. Shop Drawings: Showing layouts of panels on walls and roofs, details of edge conditions, joints, corners, panel profiles, supports, anchorages, trim flashing, closures, and special details. Distinguish between factory and field assembly work.
1.4 QUALITY ASSURANCE
A. Wind Uplift: Provide fascia panel system including supports meeting requirements of Underwriters Laboratories, Inc. for Class 90 wind uplift resistance.
B. Field Measurements: Where possible, prior to fabrication of panels, take field measurements of structure or substrates to receive panel system. Allow for trimming panel units where final dimensions cannot be established prior to fabrication.
BC&A MANUFACTURERED FASCIA JVWCD AND SOFFIT PANELS CENTRAL PIPELINE PROJECT PAGE 07410-1 1.5 DELIVERY, STORAGE, AND HANDLING
A. Deliver panels and other components so they will not be damaged or deformed. Package wall and roof panels for protection against transportation damage.
B. Handling: Exercise care in unloading, storing, and erecting wall and roof covering panels to prevent bending, warping, twisting, and surface damage.
C. Stack materials on platforms or pallets, covered with tarpaulins or other suitable weathertight ventilated covering. Store metal wall and roof panels so that they will not accumulate water. Do not store panels in contract with other materials that might cause staining, denting, or other surface damage.
1.6 WARRANTY
A. Finish Warranty: furnish panel manufacturer's written warranty covering failure of the factory-applied exterior finish on metal roof panels within the warranty period. This warranty shall be in addition to and not a limitation of other rights the Owner may have against the Contractor under the Contract Documents.
B. Warranty period for factory-applied exterior finishes on wall and roof panels is 20 years after the date of Substantial Completion.
PART 2 – PRODUCTS
2.1 MANUFACTURERS
A. Approved Manufacturer: Subject to compliance with requirements, provide fascia and soffit by one of the following:
1. Vee-Panel a. Berridge Mfr. Co. (or approved equal).
2.2 MATERIALS
A. Structural Quality Galvanized Steel Sheet: Hot-dip zinc-coated steel sheet complying with ASTM A 446 with G90 coating complying with ASTM A 525, Grade C or to suit manufacturer's standards.
1. Face Sheets: Fabricate Fascia panel face sheets to the profile or configuration indicated from 24-gage (0.0239-inch) zinc-coated steel sheets. 2. Profile: 3/8" to 3/4" high.
BC&A MANUFACTURERED FASCIA JVWCD AND SOFFIT PANELS CENTRAL PIPELINE PROJECT PAGE 07410-2 B. General: Apply coatings either before or after forming and fabricating panels, as required by coating process and as required for maximum coating performance capability. Protect coating either by application of strippable film or by packing plastic film or other suitable material between panels in a manner to properly protect the finish. Furnish air-drying spray finish in matching color for touch-up.
1. Color: "Kynar" paint system. Selected by Contracting Officer from premium color range, dark pigments. 2. Fluoropolymer Coating: Manufacturer's standard two-coat, thermo-cured, full- strength 70 percent "Kynar 500" coating consisting of a primer and a minimum 0.75- mil dry film thickness with a total minimum dry film thickness of 0.9 mil and 30 percent reflective gloss when tested in accordance with ASTM D 523. a. Durability: Provide coating that has been field tested under normal range or weathering conditions for minimum of 20 years without significant peel, blister, flake, chip, crack, or check in finish; without chalking in excess of No. 8 in accordance with ASTM D 659; and without fading in excess of 5 NBS units.
C. Fasteners: Self-tapping screws, bolts, nuts, self-locking rivets, self-locking bolts, end- welded studs, and other suitable fasteners designed to withstand design loads.
1. Use corrosion-resistant steel, or stainless steel fasteners for exterior application. 2. Provide exposed fasteners with heads matching color of roof or wall panel by means of plastic caps or factory-applied coating. 3. Locate and space exposed fasteners in true vertical and horizontal alignment. Use proper tools to obtain controlled uniform compression for positive seal without rupture of neoprene washer.
D. Accessories: Except as indicated as work of another specification section, provide components required for a complete roof or wall panel system, including trim, copings, fascias, gravel stops, mullions, sills, corner units, ridge closures, clips, seam covers, battens, flashings, gutters, louvers, sealants, gaskets, fillers, closure strips and similar items. Match materials and finishes of panels.
1. Closure Strips: Closed-cell, self-extinguishing, expanded cellular rubber or cross- linked polyolefin foam flexible closure strips. Cut or premold to match configuration of roof and wall panels. Provide closure strips where indicated or necessary to ensure weathertight construction. 2. Sealing Tape: Pressure-sensitive 100 percent solids polyisobutylene compound sealing tape with release paper backing. Provide permanently elastic, nonsag, nontoxic, nonstaining tape. 3. Joint Sealant: One-part elastomeric polyurethane, polysulfide, or silicone rubber sealant as recommended by the fascia manufacturer.
BC&A MANUFACTURERED FASCIA JVWCD AND SOFFIT PANELS CENTRAL PIPELINE PROJECT PAGE 07410-3 PART 3 – EXECUTION
3.1 INSTALLATION
A. Girts, purlin, and other secondary structural panel support members and anchorage shall be installed in accordance with AISC Manual of Steel Construction "Code of Standard Practice."
B. Panel. Comply with manufacturers' instructions and recommendations for installation, as applicable to project conditions and supporting substrates. Anchor panels and other components of the Work securely in place, with provisions for thermal and structural movement.
1. Field cutting of exterior panels by torch is not permitted. 2. Install panels with concealed fasteners.
C. Accessories: Install components required for a complete fascia panel system, including trim, copings, fascias, gravel stops, ridge closures, clips, seam covers, flashings, gutters, sealants, gaskets, fillers, closure strips, and similar items.
D. Joint Sealers: Install gaskets, joint fillers, and sealants where indicated and where required for weatherproof performance of panel systems. Provide types of gaskets, sealants, and fillers indicated or, if not otherwise indicated, types recommended by panel manufacturer.
1. Refer to other sections of these specifications for product and installation requirements applicable to indicated joint sealers.
E. Installation Tolerances: Shim and align panel units within installed tolerance of 1/4 inch in 20'-0" on level/plumb/slope and location/line as indicated, and within 1/8-inch offset of adjoining faces and of alignment of matching profiles.
3.2 CLEANING AND PROTECTION
A. Damaged Units: Replace panels and other components of the Work that have been damaged or have deteriorated beyond successful repair by means of finish touch-up or similar minor repair procedures.
B. Cleaning: Remove temporary protective coverings and strippable films (if any) as soon as each panel is installed. Upon completion of panel installation, clean finished surfaces as recommended by panel manufacturer, and maintain in a clean condition during construction.
END OF SECTION
BC&A MANUFACTURERED FASCIA JVWCD AND SOFFIT PANELS CENTRAL PIPELINE PROJECT PAGE 07410-4 SECTION 07411 METAL ROOF PANELS
PART 1 -– GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section includes the following:
1. Factory-formed and field-assembled, standing-seam metal roof panels. 2. Metal soffit panels.
B. Related Sections include the following:
1. Division 5 Section "Steel Deck" for steel roof deck supporting metal roof panels. 2. Division 7 Section "Sheet Metal Flashing and Trim" for flashings and other sheet metal work not part of metal roof panel assemblies. 3. Division 7 Section "Joint Sealants" for field-applied sealants not otherwise specified in this Section.
1.3 DEFINITIONS
A. Metal Roof Panel Assembly: Metal roof panels, attachment system components, miscellaneous metal framing, thermal insulation, and accessories necessary for a complete weathertight roofing system.
1.4 PERFORMANCE REQUIREMENTS
A. General: Provide metal roof panel assemblies that comply with performance requirements specified as determined by testing manufacturers' standard assemblies similar to those indicated for this Project, by a qualified testing and inspecting agency.
B. Air Infiltration: Air leakage through assembly of not more than 0.06 cfm/sq. ft. (0.3 L/s per sq. m) of roof area when tested according to ASTM E 283.
C. Water Penetration: No water penetration when tested according to ASTM E 331.
D. Wind-Uplift Resistance: Provide metal roof panel assemblies that comply with UL 580 for wind-uplift resistance class indicated.
BC&A METAL ROOF PANELS JVWCD PAGE 07411-1 CENTRAL PIPELINE PROJECT E. FMG Listing: Provide metal roof panels and component materials that comply with requirements in FMG 4471 as part of a panel roofing system and that are listed in FMG's "Approval Guide" for Class 1 or noncombustible construction, as applicable. Identify materials with FMG markings.
1. Fire/Windstorm Classification: Class 1A-90. 2. Hail Resistance: SH.
F. Structural Performance: Provide metal roof panel assemblies capable of withstanding the effects of gravity loads and the following loads and stresses within limits and under conditions indicated, based on testing according to ASTM E 330:
1. Wind Loads: Determine loads based on the following minimum design wind pressures: a. Uniform pressure as indicated on Drawings.
G. Thermal Movements: Provide metal roof panel assemblies that allow for thermal movements resulting from the following maximum change (range) in ambient and surface temperatures by preventing buckling, opening of joints, overstressing of components, failure of joint sealants, failure of connections, and other detrimental effects. Base engineering calculation on surface temperatures of materials due to both solar heat gain and nighttime- sky heat loss.
1. Temperature Change (Range): 120 deg F (67 deg C), ambient; 180 deg F (100 deg C), material surfaces.
1.5 SUBMITTALS
A. Product Data: Include construction details, material descriptions, dimensions of individual components and profiles, and finishes for each type of metal roof panel and accessory.
B. Shop Drawings: Show fabrication and installation layouts of metal roof panels; details of edge conditions, joints, panel profiles, corners, anchorages, trim, flashings, closures, and accessories; and special details. Distinguish between factory- and field-assembled work.
1. Accessories: Include details of the following items, at a scale of not less than 1-1/2 inches per 12 inches (1:10): a. Flashing and trim. b. Gutters. c. Downspouts. d. Roof curbs. e. Snow guards.
C. Coordination Drawings: Roof plans drawn to scale and coordinating penetrations and roof-mounted items. Show the following:
1. Roof panels and attachments. 2. Roof-mounted items including roof hatches, equipment supports, pipe supports and penetrations, lighting fixtures, snow guards, and items mounted on roof curbs.
BC&A METAL ROOF PANELS JVWCD PAGE 07411-2 CENTRAL PIPELINE PROJECT D. Samples for Selection: For each type of metal roof panel indicated with factory-applied color finishes.
1. Include similar Samples of trim and accessories involving color selection.
E. Qualification Data: For Installer.
F. Maintenance Data: For metal roof panels to include in maintenance manuals.
G. Warranties: Special warranties specified in this Section.
1.6 QUALITY ASSURANCE
A. Installer Qualifications: An employer of workers trained and approved by manufacturer.
1. Installer's responsibilities include fabricating and installing metal roof panel assemblies.
B. Source Limitations: Obtain each type of metal roof panels through one source from a single manufacturer.
C. Product Options: Drawings indicate size, profiles, and dimensional requirements of metal roof panels and are based on the specific system indicated. Refer to Division 1 Section "Product Requirements."
1. Do not modify intended aesthetic effects, as judged solely by Architect, except with Architect's approval. If modifications are proposed, submit comprehensive explanatory data to Architect for review.
D. Surface-Burning Characteristics: Provide insulation material with the following surface-burning characteristics as determined by testing identical products per ASTM E 84 by UL or another testing and inspecting agency acceptable to authorities having jurisdiction:
1. Flame-Spread Index: 25 or less, unless otherwise indicated. 2. Smoke-Developed Index: 450 or less, unless otherwise indicated.
E. Preliminary Roofing Conference: Before starting roof sheathing construction, conduct conference at Project site. Comply with requirements for preinstallation conferences in Division 1 Section "Project Management and Coordination." Review methods and procedures related to roof sheathing construction and metal roof panels including, but not limited to, the following:
1. Meet with Owner, Architect, Owner's insurer if applicable, testing and inspecting agency representative, metal roof panel Installer, metal roof panel manufacturer's representative, sheathing Installer, and installers whose work interfaces with or affects metal roof panels including installers of roof accessories and roof-mounted equipment. 2. Review and finalize construction schedule and verify availability of materials, Installer's personnel, equipment, and facilities needed to make progress and avoid delays.
BC&A METAL ROOF PANELS JVWCD PAGE 07411-3 CENTRAL PIPELINE PROJECT 3. Review methods and procedures related to metal roof panel installation, including manufacturer's written instructions. 4. Examine sheathing conditions for compliance with requirements, including flatness and attachment to structural members. 5. Review structural loading limitations of sheathing during and after roofing. 6. Review flashings, special roof details, roof drainage, roof penetrations, equipment curbs, and condition of other construction that will affect metal roof panels. 7. Review governing regulations and requirements for insurance, certificates, and testing and inspecting if applicable. 8. Review temporary protection requirements for metal roof panels during and after installation. 9. Review roof observation and repair procedures after metal roof panel installation.
1.7 DELIVERY, STORAGE, AND HANDLING
A. Deliver components, sheets, metal roof panels, and other manufactured items so as not to be damaged or deformed. Package metal roof panels for protection during transportation and handling.
B. Unload, store, and erect metal roof panels in a manner to prevent bending, warping, twisting, and surface damage.
C. Stack metal roof panels on platforms or pallets, covered with suitable weathertight and ventilated covering. Store metal roof panels to ensure dryness. Do not store metal roof panels in contact with other materials that might cause staining, denting, or other surface damage.
D. Protect strippable protective covering on metal roof panels from exposure to sunlight and high humidity, except to extent necessary for period of metal roof panel installation.
E. Protect foam-plastic insulation as follows:
1. Do not expose to sunlight, except to extent necessary for period of installation and concealment. 2. Protect against ignition at all times. Do not deliver foam-plastic insulation materials to Project site before installation time. 3. Complete installation and concealment of plastic materials as rapidly as possible in each area of construction.
1.8 PROJECT CONDITIONS
A. Weather Limitations: Proceed with installation only when existing and forecasted weather conditions permit assembly of metal roof panels to be performed according to manufacturers' written instructions and warranty requirements.
B. Field Measurements: Verify locations of roof framing and roof opening dimensions by field measurements before metal roof panel fabrication and indicate measurements on Shop Drawings.
1. Established Dimensions: Where field measurements cannot be made without delaying the Work, either establish framing and opening dimensions and proceed
BC&A METAL ROOF PANELS JVWCD PAGE 07411-4 CENTRAL PIPELINE PROJECT with fabricating metal roof panels without field measurements, or allow for field-trimming of panels. Coordinate roof construction to ensure that actual building dimensions, locations of structural members, and openings correspond to established dimensions.
1.9 COORDINATION
A. Coordinate installation of roof curbs, equipment supports, and roof penetrations, which are specified in Division 7 Section "Roof Accessories."
B. Coordinate metal panel roof assemblies with rain drainage work, flashing, trim, and construction of walls, and other adjoining work to provide a leakproof, secure, and noncorrosive installation.
1.10 WARRANTY
A. Special Warranty on Panel Finishes: Manufacturer's standard form in which manufacturer agrees to repair finish or replace metal roof panels that show evidence of deterioration of factory-applied finishes within specified warranty period.
1. Fluoropolymer Finish: Deterioration includes, but is not limited to, the following: a. Color fading more than 5 Hunter units when tested according to ASTM D 2244. b. Chalking in excess of a No. 8 rating when tested according to ASTM D 4214. c. Cracking, checking, peeling, or failure of paint to adhere to bare metal. 2. Finish Warranty Period: 20 years from date of Substantial Completion.
B. Special Weathertightness Warranty: Manufacturer's standard form in which manufacturer agrees to repair or replace metal roof panel assemblies that fail to remain weathertight, including leaks, within specified warranty period.
1. Weathertight Warranty Period: Five years from date of Substantial Completion.
PART 2 – PRODUCTS
2.1 MANUFACTURERS
A. In other Part 2 articles where titles below introduce lists, the following requirements apply for product selection:
1. Available Products: Subject to compliance with requirements, products that may be incorporated into the Work include, but are not limited to, the products specified. 2. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the manufacturers specified.
BC&A METAL ROOF PANELS JVWCD PAGE 07411-5 CENTRAL PIPELINE PROJECT 2.2 PANEL MATERIALS
A. Metallic-Coated Steel Sheet Prepainted with Coil Coating: Steel sheet metallic coated by the hot-dip process and prepainted by the coil-coating process to comply with ASTM A 755/A 755M.
1. Zinc-Coated (Galvanized) Steel Sheet: ASTM A 653/A 653M, G90 (Z275) coating designation; structural quality. 2. Surface: Smooth, flat finish. 3. Exposed Finishes: Apply the following coil coating, as specified or indicated on Drawings. a. High-Performance Organic Finish: Prepare, pretreat, and apply coating to exposed metal surfaces to comply with coating and resin manufacturers' written instructions. 1) Fluoropolymer Three-Coat System: Manufacturer's standard three-coat, thermocured system consisting of specially formulated inhibitive primer, fluoropolymer color coat, and clear fluoropolymer topcoat, with both color coat and clear topcoat containing not less than 70 percent polyvinylidene fluoride resin by weight, with a minimum total dry film thickness of 1.5 mil (0.038 mm); complying with physical properties and coating performance requirements of AAMA 2605, except as modified below: a) Humidity Resistance: 2000 hours. b) Water Resistance: 2000 hours. 4. Concealed Finish: Apply pretreatment and manufacturer's standard white or light-colored acrylic or polyester backer finish, consisting of prime coat and wash coat with a minimum total dry film thickness of 0.5 mil (0.013 mm).
B. Panel Sealants:
1. Sealant Tape: Pressure-sensitive, 100 percent solids, gray polyisobutylene compound sealant tape with release-paper backing. Provide permanently elastic, nonsag, nontoxic, nonstaining tape 1/2 inch (13 mm) wide and 1/8 inch (3 mm) thick. 2. Joint Sealant: ASTM C 920; elastomeric polyurethane, polysulfide, or silicone sealant; of type, grade, class, and use classifications required to seal joints in metal roof panels and remain weathertight; and as recommended in writing by metal roof panel manufacturer.
2.3 THERMAL INSULATION FOR FIELD-ASSEMBLED METAL ROOF PANELS
A. Faced, Polyisocyanurate Board Insulation: ASTM C 1289, Type V, oriented-strand-board facing, with maximum flame-spread and smoke-developed indexes of 75 and 450, respectively, based on tests performed on unfaced core. With cross vent 1.5” air space to provide cold-roof system (Atlas Roofing Cross vent system, Hunter Cool-Vent, or approved equal). Mechanically attached to deck.
BC&A METAL ROOF PANELS JVWCD PAGE 07411-6 CENTRAL PIPELINE PROJECT 2.4 UNDERLAYMENT MATERIALS
A. Felts: ASTM D 226, Type II (No. 30), asphalt-saturated organic felts.
B. Self-Adhering, Polyethylene-Faced Sheet: ASTM D 1970, 40 mils (1.0 mm) thick minimum, consisting of slip-resisting polyethylene-film reinforcing and top surface laminated to SBS-modified asphalt adhesive, with release-paper backing; cold applied.
1. Available Products: a. Carlisle Coatings & Waterproofing, Div. of Carlisle Companies Inc.; Dri-Start "A." b. Grace, W. R. & Co.; Grace Ice and Water Shield. c. Johns Manville International, Inc.; Roof Defender. d. Owens Corning; WeatherLock. e. Protecto Wrap Company; Rainproof TM.
C. Slip Sheet: Building paper, minimum 5 lb/100 sq. ft. (0.24 kg/sq. m), rosin sized.
D. Vapor barrier (Carlisle CCW705 or approved equal.) Over ¼” roof board substrate (Densdeck or approved equal).
2.5 MISCELLANEOUS MATERIALS
A. Fasteners: Self-tapping screws, bolts, nuts, self-locking rivets and bolts, end-welded studs, and other suitable fasteners designed to withstand design loads. Provide exposed fasteners with heads matching color of metal roof panels by means of plastic caps or factory-applied coating.
1. Fasteners for Roof Panels: Self-drilling or self-tapping, zinc-plated, hex-head carbon-steel screws, with a stainless-steel cap or zinc-aluminum-alloy head and EPDM or neoprene sealing washer. 2. Fasteners for Flashing and Trim: Blind fasteners or self-drilling screws with hex washer head. 3. Blind Fasteners: High-strength aluminum or stainless-steel rivets.
B. Bituminous Coating: Cold-applied asphalt mastic, SSPC-Paint 12, compounded for 15-mil (0.4-mm) dry film thickness per coat. Provide inert-type noncorrosive compound free of asbestos fibers, sulfur components, and other deleterious impurities.
2.6 STANDING-SEAM METAL ROOF PANELS
A. General: Provide factory-formed metal roof panels designed to be field assembled by lapping and interconnecting raised side edges of adjacent panels with joint type indicated and mechanically attaching panels to supports using concealed clips in side laps. Include clips, cleats, pressure plates, and accessories required for weathertight installation.
1. Steel Panel Systems: Unless more stringent requirements are indicated, comply with ASTM E 1514.
BC&A METAL ROOF PANELS JVWCD PAGE 07411-7 CENTRAL PIPELINE PROJECT B. Vertical-Rib, Seamed-Joint, Standing-Seam Metal Roof Panels: Formed with vertical ribs at panel edges and intermediate stiffening ribs symmetrically spaced between ribs; designed for sequential installation by mechanically attaching panels to supports using concealed clips located under one side of panels and engaging opposite edge of adjacent panels, and mechanically seaming panels together.
1. Basis-of-Design Product: Berridge Manufacturing Company, ZEE-Lock Panel or a comparable product of one of the following: 2. Available Manufacturers: a. AEP-Span. b. BHP Steel Building Products USA Inc. c. CENTRIA Architectural Systems. d. MBCI; Div. of NCI Building Systems. 3. Material: Zinc-coated (galvanized) steel sheet, 0.0269 inch (0.70 mm) thick. a. Exterior Finish: Fluoropolymer. b. Color: As selected by Architect from manufacturer's full range. 4. Batten: Same material, finish, and color as roof panels. 5. Clips: Floating to accommodate thermal movement. a. Material: 0.0528-inch- (1.35-mm-) thick, zinc-coated (galvanized) steel sheet. 6. Joint Type: Single folded. 7. Weatherseal: Provide factory applied extruded vinyl weatherseal. 8. Panel Coverage: 16 inches (406 mm). 9. Panel Height: 2.0 inches (51 mm). 10. Uplift Rating: UL 90.
2.7 METAL SOFFIT PANELS
A. General: Provide factory-formed metal soffit panels designed to be field assembled by lapping and interconnecting side edges of adjacent panels and mechanically attaching through panel to supports using concealed fasteners and factory-applied sealant in side laps. Include accessories required for weathertight installation.
B. Flush-Profile Metal Soffit Panels: Solid panels formed with vertical panel edges and flat pan between panel edges; with flush joint between panels.
1. Basis-of-Design Product: Berridge Manufacturing Company, Flush Seam Panel or a comparable product of one of the following:Available Manufacturers: a. AEP-Span. b. BHP Steel Building Products USA Inc. c. CENTRIA Architectural Systems. d. MBCI; Div. of NCI Building Systems. 3. Material: Zinc-coated (galvanized) steel sheet, 0.0269 inch (0.70 mm) thick. a. Exterior Finish: Fluoropolymer. b. Color: As selected by Architect from manufacturer's full range. 4. Panel Coverage: 3-7/8 inches (98.33 mm). 5. Panel Height: 0.500 inch (13 mm)Sealant: Factory applied within interlocking joint.
BC&A METAL ROOF PANELS JVWCD PAGE 07411-8 CENTRAL PIPELINE PROJECT 2.8 ACCESSORIES
A. Roof Panel Accessories: Provide components required for a complete metal roof panel assembly including trim, copings, fasciae, corner units, ridge closures, clips, flashings, sealants, gaskets, fillers, closure strips, and similar items. Match material and finish of metal roof panels, unless otherwise indicated.
1. Closures: Provide closures at eaves and ridges, fabricated of same metal as metal roof panels. 2. Clips: Minimum 0.0625-inch- (1.6-mm-) thick, stainless-steel panel clips designed to withstand negative-load requirements. 3. Cleats: Mechanically seamed cleats formed from minimum 0.0250-inch- (0.64-mm-) thick, stainless-steel or nylon-coated aluminum sheet. 4. Backing Plates: Provide metal backing plates at panel end splices, fabricated from material recommended by manufacturer. 5. Closure Strips: Closed-cell, expanded, cellular, rubber or crosslinked, polyolefin-foam or closed-cell laminated polyethylene; minimum 1-inch- (25-mm-) thick, flexible closure strips; cut or premolded to match metal roof panel profile. Provide closure strips where indicated or necessary to ensure weathertight construction.
B. Flashing and Trim: Formed from 0.0179-inch- (0.45-mm-) thick, zinc-coated (galvanized) steel sheet prepainted with coil coating. Provide flashing and trim as required to seal against weather and to provide finished appearance. Locations include, but are not limited to, eaves, rakes, corners, bases, framed openings, ridges, fasciae, and fillers. Finish flashing and trim with same finish system as adjacent metal roof panels.
C. Gutters: Formed from 0.0179-inch- (0.45-mm-) thick, zinc-coated (galvanized) steel sheet prepainted with coil coating. Match profile of gable trim, complete with end pieces, outlet tubes, and other special pieces as required. Fabricate in minimum 96-inch- (2400-mm-) long sections, sized according to SMACNA's "Architectural Sheet Metal Manual." Furnish gutter supports spaced 36 inches (900 mm) o.c., fabricated from same metal as gutters. Provide bronze, copper, or aluminum wire ball strainers at outlets. Finish gutters to match roof fascia and rake trim.
D. Downspouts: Formed from 0.0179-inch- (0.45-mm-) thick, zinc-coated (galvanized) steel sheet prepainted with coil coating; in 10-foot- (3-m-) long sections, complete with formed elbows and offsets. Finish downspouts to match metal roof panels.
BC&A METAL ROOF PANELS JVWCD PAGE 07411-9 CENTRAL PIPELINE PROJECT E. Snow Guards: Prefabricated, noncorrosive units designed to be installed without penetrating metal roof panels, and complete with predrilled holes, clamps, or hooks for anchoring.
1. Seam-Mounted, Stop-Type Snow Guards: Cast-aluminum stops designed for attachment to vertical ribs of standing-seam metal roof panels with stainless-steel set screws. a. Products: Subject to compliance with requirements, available products that may be incorporated into the Work include, but are not limited to, the following: 1) Alpine SnowGuards, Div. of Vermont Slate & Copper Services, Inc. 2) Berger Bros. Co. 3) Polar Blox.
F. Pipe Flashing: Premolded, EPDM pipe collar with flexible aluminum ring bonded to base.
2.9 FABRICATION
A. General: Fabricate and finish metal roof panels and accessories at the factory to greatest extent possible, by manufacturer's standard procedures and processes, as necessary to fulfill indicated performance requirements demonstrated by laboratory testing. Comply with indicated profiles and with dimensional and structural requirements.
B. Provide panel profile, including major ribs and intermediate stiffening ribs, if any, for full length of panel.
C. Where indicated, fabricate metal roof panel joints with factory-installed captive gaskets or separator strips that provide a tight seal and prevent metal-to-metal contact, in a manner that will minimize noise from movements within panel assembly.
D. Sheet Metal Accessories: Fabricate flashing and trim to comply with recommendations in SMACNA's "Architectural Sheet Metal Manual" that apply to the design, dimensions, metal, and other characteristics of item indicated.
1. Form exposed sheet metal accessories that are without excessive oil canning, buckling, and tool marks and that are true to line and levels indicated, with exposed edges folded back to form hems. 2. Seams for Other Than Aluminum: Fabricate nonmoving seams in accessories with flat-lock seams. Tin edges to be seamed, form seams, and solder. 3. Sealed Joints: Form nonexpansion but movable joints in metal to accommodate elastomeric sealant to comply with SMACNA standards. 4. Conceal fasteners and expansion provisions where possible. Exposed fasteners are not allowed on faces of accessories exposed to view. 5. Fabricate cleats and attachment devices from same material as accessory being anchored or from compatible, noncorrosive metal recommended by metal roof panel manufacturer. a. Size: As recommended by SMACNA's "Architectural Sheet Metal Manual" or metal roof panel manufacturer for application but not less than thickness of metal being secured.
BC&A METAL ROOF PANELS JVWCD PAGE 07411-10 CENTRAL PIPELINE PROJECT 2.10 FINISHES, GENERAL
A. Comply with NAAMM's "Metal Finishes Manual for Architectural and Metal Products" for recommendations for applying and designating finishes.
B. Protect mechanical and painted finishes on exposed surfaces from damage by applying a strippable, temporary protective covering before shipping.
C. Appearance of Finished Work: Variations in appearance of abutting or adjacent pieces are acceptable if they are within one-half of the range of approved Samples. Noticeable variations in the same piece are not acceptable. Variations in appearance of other components are acceptable if they are within the range of approved Samples and are assembled or installed to minimize contrast.
PART 3 – EXECUTION
3.1 EXAMINATION
A. Examine substrates, areas, and conditions, with Installer present, for compliance with requirements for installation tolerances, metal roof panel supports, and other conditions affecting performance of work.
1. Examine solid roof sheathing to verify that sheathing joints are supported by framing or blocking and that installation is within flatness tolerances required by metal roof panel manufacturer.
B. Examine roughing-in for components and systems penetrating metal roof panels to verify actual locations of penetrations relative to seam locations of metal roof panels before metal roof panel installation.
C. Proceed with installation only after unsatisfactory conditions have been corrected.
3.2 PREPARATION
A. Clean substrates of substances harmful to insulation, including removing projections capable of interfering with insulation attachment.
B. Install flashings and other sheet metal to comply with requirements specified in Division 7 Section "Sheet Metal Flashing and Trim."
C. Miscellaneous Framing: Install subpurlins, eave angles, furring, and other miscellaneous roof panel support members and anchorage according to metal roof panel manufacturer's written recommendations.
BC&A METAL ROOF PANELS JVWCD PAGE 07411-11 CENTRAL PIPELINE PROJECT 3.3 THERMAL INSULATION INSTALLATION FOR FIELD-ASSEMBLED METAL ROOF PANELS
A. Board Insulation: Extend insulation in thickness indicated to cover entire roof. Comply with installation requirements in Division 7 Section "Building Insulation."
1. Erect insulation horizontally and hold in place with Z-shaped furring members spaced 24 inches (610 mm) o.c. Securely attach narrow flanges of furring members to roof deck with screws spaced 24 inches (600 mm) o.c.
3.4 UNDERLAYMENT INSTALLATION
A. Felt Underlayment: Install felt underlayment and building-paper slip sheet on roof sheathing under metal roof panels, unless otherwise recommended by metal roof panel manufacturer. Use adhesive for temporary anchorage, where possible, to minimize use of mechanical fasteners under metal roof panels. Apply at locations indicated below, in shingle fashion to shed water, with lapped joints of not less than 2 inches (50 mm).
1. Apply on roof not covered by self-adhering sheet underlayment. Lap edges of self-adhering sheet underlayment not less than 3 inches (75 mm), in shingle fashion to shed water.
B. Self-Adhering Sheet Underlayment: Install self-adhering sheet underlayment, wrinkle free, on roof sheathing under metal roof panels. Apply primer if required by manufacturer. Comply with temperature restrictions of underlayment manufacturer for installation; use primer rather than nails for installing underlayment at low temperatures. Apply at locations indicated below, in shingle fashion to shed water, with end laps of not less than 6 inches (150 mm) staggered 24 inches (600 mm) between courses. Overlap side edges not less than 3-1/2 inches (90 mm). Roll laps with roller. Cover underlayment within 14 days.
1. Roof perimeter for a distance up from eaves of 24 inches (600 mm) beyond interior wall line. 2. Valleys, from lowest point to highest point, for a distance on each side of 18 inches (460 mm). Overlap ends of sheets not less than 6 inches (150 mm). 3. Rake edges for a distance of 18 inches (460 mm). 4. Hips and ridges for a distance on each side of 12 inches (300 mm). 5. Roof to wall intersections for a distance from wall of 18 inches (460 mm). 6. Around dormers, chimneys, skylights, and other penetrating elements for a distance from element of 18 inches (460 mm).
C. Install flashings to cover underlayment to comply with requirements specified in Division 7 Section "Sheet Metal Flashing and Trim."
D. Apply slip sheet over underlayment before installing metal roof panels.
BC&A METAL ROOF PANELS JVWCD PAGE 07411-12 CENTRAL PIPELINE PROJECT 3.5 METAL ROOF PANEL INSTALLATION, GENERAL
A. General: Provide metal roof panels of full length from eave to ridge, unless otherwise indicated or restricted by shipping limitations. Anchor metal roof panels and other components of the Work securely in place, with provisions for thermal and structural movement.
1. Field cutting of metal roof panels by torch is not permitted. 2. Rigidly fasten eave end of metal roof panels and allow ridge end free movement due to thermal expansion and contraction. Predrill panels. 3. Provide metal closures at peaks, rake edges, each side of ridge and hip caps. 4. Flash and seal metal roof panels with weather closures at eaves, rakes, and at perimeter of all openings. Fasten with self-tapping screws. 5. Locate and space fastenings in uniform vertical and horizontal alignment. 6. Install ridge and hip caps as metal roof panel work proceeds. 7. Locate panel splices over, but not attached to, structural supports. Stagger panel splices and end laps to avoid a four-panel lap splice condition. 8. Lap metal flashing over metal roof panels to allow moisture to run over and off the material.
B. Fasteners:
1. Steel Roof Panels: Use stainless-steel fasteners for surfaces exposed to the exterior and galvanized steel fasteners for surfaces exposed to the interior.
C. Metal Protection: Where dissimilar metals will contact each other or corrosive substrates, protect against galvanic action by painting contact surfaces with bituminous coating, by applying rubberized-asphalt underlayment to each contact surface, or by other permanent separation as recommended by metal roof panel manufacturer.
D. Joint Sealers: Install gaskets, joint fillers, and sealants where indicated and where required for weatherproof performance of metal roof panel assemblies. Provide types of gaskets, fillers, and sealants indicated or, if not indicated, types recommended by metal roof panel manufacturer.
1. Seal metal roof panel end laps with double beads of tape or sealant, full width of panel. Seal side joints where recommended by metal roof panel manufacturer. 2. Prepare joints and apply sealants to comply with requirements in Division 7 Section "Joint Sealants."
BC&A METAL ROOF PANELS JVWCD PAGE 07411-13 CENTRAL PIPELINE PROJECT 3.6 FIELD-ASSEMBLED METAL ROOF PANEL INSTALLATION
A. Standing-Seam Metal Roof Panels: Fasten metal roof panels to supports with concealed clips at each standing-seam joint at location, spacing, and with fasteners recommended by manufacturer.
1. Install clips to supports with self-tapping fasteners. 2. Install pressure plates at locations indicated in manufacturer's written installation instructions. 3. Seamed Joint: Crimp standing seams with manufacturer-approved motorized seamer tool so clip, metal roof panel, and factory-applied sealant are completely engaged.
3.7 ACCESSORY INSTALLATION
A. General: Install accessories with positive anchorage to building and weathertight mounting and provide for thermal expansion. Coordinate installation with flashings and other components.
1. Install components required for a complete metal roof panel assembly including trim, copings, ridge closures, seam covers, flashings, sealants, gaskets, fillers, closure strips, and similar items.
B. Flashing and Trim: Comply with performance requirements, manufacturer's written installation instructions, and SMACNA's "Architectural Sheet Metal Manual." Provide concealed fasteners where possible, and set units true to line and level as indicated. Install work with laps, joints, and seams that will be permanently watertight and weather resistant.
1. Install exposed flashing and trim that is without excessive oil canning, buckling, and tool marks and that is true to line and levels indicated, with exposed edges folded back to form hems. Install sheet metal flashing and trim to fit substrates and to result in waterproof and weather-resistant performance. 2. Expansion Provisions: Provide for thermal expansion of exposed flashing and trim. Space movement joints at a maximum of 10 feet (3 m) with no joints allowed within 24 inches (600 mm) of corner or intersection. Where lapped or bayonet-type expansion provisions cannot be used or would not be sufficiently weather resistant and waterproof, form expansion joints of intermeshing hooked flanges, not less than 1 inch (25 mm) deep, filled with mastic sealant (concealed within joints).
C. Gutters: Join sections with riveted and soldered or lapped and sealed joints. Attach gutters to eave with gutter hangers spaced not more than 4 feet (1.2 m) o.c. using manufacturer's standard fasteners. Provide end closures and seal watertight with sealant. Provide for thermal expansion.
D. Downspouts: Join sections with 1-1/2-inch (38-mm) telescoping joints. Provide fasteners designed to hold downspouts securely 1 inch (25 mm) away from walls; locate fasteners at top and bottom and at approximately 60 inches (1500 mm) o.c. in between.
1. Provide elbows at base of downspouts to direct water away from building.
BC&A METAL ROOF PANELS JVWCD PAGE 07411-14 CENTRAL PIPELINE PROJECT E. Snow Guards: Attach bar supports to vertical ribs of standing-seam metal roof panels with clamps or set screws. Do not use fasteners that will penetrate metal roof panels.
1. Install snow guards above entrances, adjacent to walking surfaces, at other areas where falling snow may be hazardous and at locations as recommended by the manufacturer and where directed by the Architect. Install in accordance with manufacturer=s printed instructions and recommendations.
F. Pipe Flashing: Form flashing around pipe penetration and metal roof panels. Fasten and seal to metal roof panels as recommended by manufacturer.
3.8 ERECTION TOLERANCES
A. Installation Tolerances: Shim and align metal roof panel units within installed tolerance of 1/4 inch in 20 feet (6 mm in 6 m) on slope and location lines as indicated and within 1/8-inch (3-mm) offset of adjoining faces and of alignment of matching profiles.
3.9 CLEANING AND PROTECTION
B. Remove temporary protective coverings and strippable films, if any, as metal roof panels are installed, unless otherwise indicated in manufacturer's written installation instructions. On completion of metal roof panel installation, clean finished surfaces as recommended by metal roof panel manufacturer. Maintain in a clean condition during construction.
C. Replace metal roof panels that have been damaged or have deteriorated beyond successful repair by finish touchup or similar minor repair procedures.
END OF SECTION
BC&A METAL ROOF PANELS JVWCD PAGE 07411-15 CENTRAL PIPELINE PROJECT
SECTION 07620 SHEET METAL FLASHING AND TRIM
PART 1 – GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section includes the following sheet metal flashing and trim:
1. Manufactured reglets. 2. Formed roof drainage system. 3. Formed low-slope roof flashing and trim. 4. Formed wall flashing and trim. 5. Formed equipment support flashing.
B. Related Sections include the following:
1. Division 4 Section "Unit Masonry Assemblies" for installing through-wall flashing, reglets, and other sheet metal flashing and trim. 2. Division 7 Section "Metal Roof Panels" for factory-formed metal roof panels and flashing and trim not part of sheet metal flashing and trim. 3. Division 7 Section "Roof Accessories" for set-on-type curbs, roof hatches, and other manufactured roof accessory units. 4. Division 7 Section "Joint Sealants" for field-applied sheet metal flashing and trim sealants.
1.3 PERFORMANCE REQUIREMENTS
A. General: Install sheet metal flashing and trim to withstand wind loads, structural movement, thermally induced movement, and exposure to weather without failing, rattling, leaking, and fastener disengagement.
B. Fabricate and install roof edge flashing and copings capable of resisting the following forces according to recommendations in FMG Loss Prevention Data Sheet 1-49:
1. Wind Zone 1: For velocity pressures of 21 to 30 lbf/sq. ft. (1.00 to 1.44 kPa): 60-lbf/sq. ft. (2.87-kPa) perimeter uplift force, 90-lbf/sq. ft. (4.31-kPa) corner uplift force, and 30-lbf/sq. ft. (1.44-kPa) outward force.
C. Thermal Movements: Provide sheet metal flashing and trim that allow for thermal movements resulting from the following maximum change (range) in ambient and surface temperatures by preventing buckling, opening of joints, hole elongation, overstressing of components, failure of joint sealants, failure of connections, and other detrimental effects. Provide clips that resist rotation and avoid shear stress as a result of sheet metal and trim
BC&A SHEET METAL FLASHING AND TRIM JVWCD PAGE 07620-1 CENTRAL PIPELINE PROJECT thermal movements. Base engineering calculation on surface temperatures of materials due to both solar heat gain and nighttime-sky heat loss.
1. Temperature Change (Range): 120 deg F (67 deg C), ambient; 180 deg F (100 deg C), material surfaces.
D. Water Infiltration: Provide sheet metal flashing and trim that do not allow water infiltration to building interior.
1.4 SUBMITTALS
A. Product Data: For each type of product indicated. Include construction details, material descriptions, dimensions of individual components and profiles, and finishes. Submittals shall comply with the requirements of Section 01300 – Contractor Submittals.
B. Shop Drawings: Show layouts of sheet metal flashing and trim, including plans and elevations. Distinguish between shop- and field-assembled work. Include the following:
1. Identify material, thickness, weight, and finish for each item and location in Project. 2. Details for forming sheet metal flashing and trim, including profiles, shapes, seams, and dimensions. 3. Details for fastening, joining, supporting, and anchoring sheet metal flashing and trim, including fasteners, clips, cleats, and attachments to adjoining work. 4. Details of expansion-joint covers, including showing direction of expansion and contraction.
C. Samples for Selection: For each type of sheet metal flashing and trim indicated with factory-applied color finishes.
1. Include similar Samples of trim and accessories involving color selection.
1.5 QUALITY ASSURANCE
A. Sheet Metal Flashing and Trim Standard: Comply with SMACNA's "Architectural Sheet Metal Manual." Conform to dimensions and profiles shown unless more stringent requirements are indicated.
B. Mockups: Prior to installing sheet metal flashing and trim, construct mockups indicated to verify selections made under Sample submittals and to demonstrate aesthetic effects as well as qualities of materials and execution. Build mockups to comply with the following requirements, using materials indicated for final unit of Work.
1. Locate mockups on-site in the location and of the size indicated or, if not indicated, as directed by the Engineer. 2. Notify the Engineer one week in advance of the dates and times when mockups will be constructed. 3. Demonstrate the proposed range of aesthetic effects and workmanship. 4. Construct mockups for the following type of sheet metal flashing and trim: a. Exposed trim, gravel stops, and fasciae. b. Copings. 5. Obtain Engineer's approval of mockups before start of final unit of Work.
BC&A SHEET METAL FLASHING AND TRIM JVWCD PAGE 07620-2 CENTRAL PIPELINE PROJECT 6. Retain and maintain mockups during construction in an undisturbed condition as a standard for judging the completed Work. a. When directed, demolish and remove mockups from Project site. b. Approved mockups in an undisturbed condition at the time of Substantial Completion may become part of the completed Work.
C. Preinstallation Conference: Conduct conference at Project site to comply with requirements in Division 1 Section "Project Management and Coordination."
1. Meet with Owner, Engineer, Owner's insurer if applicable, Installer, and installers whose work interfaces with or affects sheet metal flashing and trim including installers of roofing materials, roof accessories, unit skylights, and roof-mounted equipment. 2. Review methods and procedures related to sheet metal flashing and trim. 3. Examine substrate conditions for compliance with requirements, including flatness and attachment to structural members. 4. Document proceedings, including corrective measures and actions required, and furnish copy of record to each participant.
1.6 DELIVERY, STORAGE, AND HANDLING
A. Deliver sheet metal flashing materials and fabrications undamaged. Protect sheet metal flashing and trim materials and fabrications during transportation and handling.
B. Unload, store, and install sheet metal flashing materials and fabrications in a manner to prevent bending, warping, twisting, and surface damage.
C. Stack materials on platforms or pallets, covered with suitable weathertight and ventilated covering. Do not store sheet metal flashing and trim materials in contact with other materials that might cause staining, denting, or other surface damage.
1.7 COORDINATION
A. Coordinate installation of sheet metal flashing and trim with interfacing and adjoining construction to provide a leakproof, secure, and noncorrosive installation.
PART 2 – PRODUCTS
2.1 MANUFACTURERS
A. In other Part 2 articles where titles below introduce lists, the following requirements apply to product selection:
1. Available Products: Subject to compliance with requirements, products that may be incorporated into the Work include, but are not limited to, products specified. 2. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, manufacturers specified.
BC&A SHEET METAL FLASHING AND TRIM JVWCD PAGE 07620-3 CENTRAL PIPELINE PROJECT 2.2 SHEET METALS
A. Zinc-Coated (Galvanized) Steel Sheet: ASTM A 653/A 653M, G90 (Z275) coating designation; structural quality, mill phosphatized for field painting.
B. Prepainted, Metallic-Coated Steel Sheet: Steel sheet metallic coated by the hot-dip process and prepainted by the coil-coating process to comply with ASTM A 755/A 755M.
1. Zinc-Coated (Galvanized) Steel Sheet: ASTM A 653/A 653M, G90 (Z275) coating designation; structural quality. 2. Exposed Finishes: Apply the following coil coating: a. High-Performance Organic Finish: Prepare, pretreat, and apply coating to exposed metal surfaces to comply with coating and resin manufacturers' written instructions. 1) Fluoropolymer 3-Coat System: Manufacturer's standard 3-coat, thermocured system consisting of specially formulated inhibitive primer, fluoropolymer color coat, and clear fluoropolymer topcoat, with both color coat and clear topcoat containing not less than 70 percent polyvinylidene fluoride resin by weight, with a minimum total dry film thickness of 1.5 mil (0.038 mm); complying with physical properties and coating performance requirements of AAMA 2605, except as modified below: a) Humidity Resistance: 2000 hours. b) Salt-Spray Resistance: 2000 hours. 2) Color: Custom color as selected by the Owner from manufacturer's full range, to match existing, including deep tone colors.
C. Lead Sheet: ASTM B 749, Type L51121, copper-bearing lead sheet.
D. Zinc Sheet: Electrolytic, 99 percent pure zinc alloyed with 1 percent titanium and copper.
1. Finish: Bright rolled.
2.3 UNDERLAYMENT MATERIALS
A. Polyethylene Sheet: 6-mil- (0.15-mm-) thick polyethylene sheet complying with ASTM D 4397.
B. Slip Sheet: Rosin-sized paper, minimum 3 lb/100 sq. ft. (0.16 kg/sq. m).
2.4 MISCELLANEOUS MATERIALS
A. General: Provide materials and types of fasteners, solder, welding rods, protective coatings, separators, sealants, and other miscellaneous items as required for complete sheet metal flashing and trim installation.
B. Fasteners: Wood screws, annular threaded nails, self-tapping screws, self-locking rivets and bolts, and other suitable fasteners designed to withstand design loads.
1. Exposed Fasteners: Heads matching color of sheet metal by means of plastic caps or factory-applied coating.
BC&A SHEET METAL FLASHING AND TRIM JVWCD PAGE 07620-4 CENTRAL PIPELINE PROJECT 2. Fasteners for Flashing and Trim: Blind fasteners or self-drilling screws, gasketed, with hex washer head. 3. Blind Fasteners: High-strength aluminum or stainless-steel rivets. 4. Spikes and Ferrules: Same material as gutter; with spike with ferrule matching internal gutter width.
C. Solder for Lead: ASTM B 32, Grade Sn50, 50 percent tin and 50 percent lead.
D. Solder for Zinc: ASTM B 32, 60 percent lead and 40 percent tin with low antimony, as recommended by manufacturer.
E. Burning Rod for Lead: Same composition as lead sheet.
F. Sealing Tape: Pressure-sensitive, 100 percent solids, polyisobutylene compound sealing tape with release-paper backing. Provide permanently elastic, nonsag, nontoxic, nonstaining tape.
G. Elastomeric Sealant: ASTM C 920, elastomeric silicone polymer sealant; of type, grade, class, and use classifications required to seal joints in sheet metal flashing and trim and remain watertight.
H. Butyl Sealant: ASTM C 1311, single-component, solvent-release butyl rubber sealant, polyisobutylene plasticized, heavy bodied for hooked-type expansion joints with limited movement.
I. Bituminous Coating: Cold-applied asphalt mastic, SSPC-Paint 12, compounded for 15-mil (0.4-mm) dry film thickness per coat. Provide inert-type noncorrosive compound free of asbestos fibers, sulfur components, and other deleterious impurities.
2.5 MANUFACTURED SHEET METAL FLASHING AND TRIM
A. Reglets: Units of type, material, and profile indicated, formed to provide secure interlocking of separate reglet and counterflashing pieces, and compatible with flashing indicated with factory- mitered and -welded corners and junctions.
1. Available Manufacturers: a. Fry Reglet Corporation. 2. Material: Galvanized steel, 0.0217 inch (0.55 mm) thick. 3. Surface-Mounted Type: Provide with slotted holes for fastening to substrate, with neoprene or other suitable weatherproofing washers, and with channel for sealant at top edge. 4. Masonry Type: Provide with offset top flange for embedment in masonry mortar joint. a. Available Manufacturers: 1) Cheney Flashing Company, Inc., Type B Snap Lock. 5. Flexible Flashing Retainer: Provide resilient plastic or rubber accessory to secure flexible flashing in reglet where clearance does not permit use of standard metal counterflashing or where Drawings show reglet without metal counterflashing. 6. Counterflashing Wind-Restraint Clips: Provide clips to be installed before counterflashing to prevent wind uplift of counterflashing lower edge.
BC&A SHEET METAL FLASHING AND TRIM JVWCD PAGE 07620-5 CENTRAL PIPELINE PROJECT 2.6 FABRICATION, GENERAL
A. General: Custom fabricate sheet metal flashing and trim to comply with recommendations in SMACNA's "Architectural Sheet Metal Manual" that apply to design, dimensions, metal, and other characteristics of item indicated. Shop fabricate items where practicable. Obtain field measurements for accurate fit before shop fabrication.
B. Fabricate sheet metal flashing and trim in thickness or weight needed to comply with performance requirements, but not less than that specified for each application and metal.
C. Fabricate sheet metal flashing and trim without excessive oil canning, buckling, and tool marks and true to line and levels indicated, with exposed edges folded back to form hems.
1. Seams for Other Than Aluminum: Fabricate nonmoving seams in accessories with flat-lock seams. Tin edges to be seamed, form seams, and solder.
D. Sealed Joints: Form nonexpansion but movable joints in metal to accommodate elastomeric sealant to comply with SMACNA recommendations.
E. Seams: Comply with SMACNA Architectural Sheet Metal Manual@, (Sixth Edition, September 2003) Figure no. 3-2 and 3-3 as applicable to specific installations.
1. Standing Seams: Provide double lock standing seams (detail no. 25, figure no. 3-3), with finish not less than 1-1/4" high.
F. Expansion Provisions: Where lapped or bayonet-type expansion provisions in the Work cannot be used, form expansion joints of intermeshing hooked flanges, not less than 1 inch (25 mm) deep, filled with elastomeric sealant concealed within joints.
G. Conceal fasteners and expansion provisions where possible on exposed-to-view sheet metal flashing and trim, unless otherwise indicated.
H. Fabricate cleats and attachment devices from same material as accessory being anchored or from compatible, noncorrosive metal.
1. Thickness: As recommended by SMACNA's "Architectural Sheet Metal Manual" for application but not less than thickness of metal being secured.
2.7 ROOF DRAINAGE SHEET METAL FABRICATIONS
A. Hanging Gutters: Fabricate to cross section indicated, complete with end pieces, outlet tubes, and other accessories as required. Fabricate in minimum 96-inch- (2400-mm-) long sections. Furnish flat-stock gutter spacers and gutter brackets fabricated from same metal as gutters, of size recommended by SMACNA but not less than twice the gutter thickness. Fabricate expansion joints, expansion-joint covers, gutter bead reinforcing bars, and gutter accessories from same metal as gutters.
1. Gutter Style: D and as detailed. 2. Expansion Joints: Built in. 3. Accessories: Continuous removable leaf screen with sheet metal frame and hardware cloth screen.
BC&A SHEET METAL FLASHING AND TRIM JVWCD PAGE 07620-6 CENTRAL PIPELINE PROJECT 4. Gutters with Girth up to 15 Inches (380 mm): Fabricate from the following material: a. Prepainted, Metallic-Coated Steel: 0.0299 inch (0.76 mm) thick.
B. Downspouts: Fabricate rectangular downspouts complete with mitered elbows. Furnish with metal hangers, from same material as downspouts, and anchors.
1. Fabricate downspouts from the following material: a. Prepainted, Metallic-Coated Steel: 0.0299 inch (0.76 mm) thick.
2.8 LOW-SLOPE ROOF SHEET METAL FABRICATIONS
A. Copings: Fabricate in minimum 96-inch- (2400-mm-) long, but not exceeding 10-foot- (3-m-) long, sections. Fabricate joint plates of same thickness as copings. Furnish with continuous cleats to support edge of external leg and drill elongated holes for fasteners on interior leg. Miter corners, seal, and solder or weld watertight.
1. Joint Style: Standing seams. 2. Fabricate copings from the following material: a. Prepainted, Metallic-Coated Steel: 0.0396 inch (1.0 mm) thick.
B. Roof and Roof to Wall Transition Expansion-Joint Cover: Fabricate from the following material:
1. Prepainted, Metallic-Coated Steel: 0.0336 inch (0.85 mm) thick.
C. Base Flashing: Fabricate from the following material:
1. Galvanized Steel: 0.0276 inch (0.7 mm) thick.
D. Counterflashing: Fabricate from the following material:
1. Galvanized Steel: 0.0217 inch (0.55 mm) thick.
E. Flashing Receivers: Fabricate from the following material:
1. Galvanized Steel: 0.0217 inch (0.55 mm) thick.
F. Roof-Penetration Flashing: Fabricate from the following material:
1. Galvanized Steel: 0.0276 inch (0.7 mm) thick.
2.9 WALL SHEET METAL FABRICATIONS
A. Through-Wall Flashing: Fabricate continuous flashings in minimum 96-inch- (2400-mm-) long, but not exceeding 12 foot (3.6 m) long, sections, under copings, at shelf angles, and where indicated. Fabricate discontinuous lintel, sill, and similar flashings to extend 6 inches (150 mm) beyond each side of wall openings. Form with 2-inch- (50-mm-) high end dams. Fabricate from the following material:
1. Zinc: 0.040 inch (1.0 mm) thick.
BC&A SHEET METAL FLASHING AND TRIM JVWCD PAGE 07620-7 CENTRAL PIPELINE PROJECT B. Openings Flashing in Frame Construction: Fabricate head, sill, jamb, and similar flashings to extend 4 inches (100 mm) beyond wall openings. Form head and sill flashing with 2-inch- (50-mm-) high end dams. Fabricate from the following material:
1. Prepainted, Metallic-Coated Steel: 0.0217 inch (0.55 mm) thick.
C. Wall Expansion-Joint Cover: Fabricate from the following material:
1. Prepainted, Metallic-Coated Steel: 0.0276 inch (0.7 mm) thick.
2.10 MISCELLANEOUS SHEET METAL FABRICATIONS
A. Equipment Support Flashing: Fabricate from the following material:
1. Galvanized Steel: 0.0276 inch (0.7 mm) thick.
2.11 FINISHES
A. Comply with NAAMM's "Metal Finishes Manual for Architectural and Metal Products" for recommendations for applying and designating finishes.
B. Protect mechanical and painted finishes on exposed surfaces from damage by applying a strippable, temporary protective covering before shipping.
C. Appearance of Finished Work: Variations in appearance of abutting or adjacent pieces are acceptable if they are within one-half of the range of approved Samples. Noticeable variations in the same piece are not acceptable. Variations in appearance of other components are acceptable if they are within the range of approved Samples and are assembled or installed to minimize contrast.
PART 3 – EXECUTION
3.1 EXAMINATION
A. Examine substrates, areas, and conditions, with Installer present, to verify actual locations, dimensions and other conditions affecting performance of work.
1. Verify that substrate is sound, dry, smooth, clean, sloped for drainage, and securely anchored. 2. Proceed with installation only after unsatisfactory conditions have been corrected.
3.2 INSTALLATION, GENERAL
A. General: Anchor sheet metal flashing and trim and other components of the Work securely in place, with provisions for thermal and structural movement. Use fasteners, solder, welding rods, protective coatings, separators, sealants, and other miscellaneous items as required to complete sheet metal flashing and trim system.
1. Torch cutting of sheet metal flashing and trim is not permitted.
BC&A SHEET METAL FLASHING AND TRIM JVWCD PAGE 07620-8 CENTRAL PIPELINE PROJECT B. Metal Protection: Where dissimilar metals will contact each other or corrosive substrates, protect against galvanic action by painting contact surfaces with bituminous coating or by other permanent separation as recommended by fabricator or manufacturers of dissimilar metals.
1. Coat side of sheet metal flashing and trim with bituminous coating where flashing and trim will contact wood, ferrous metal, or cementitious construction. 2. Underlayment: Where installing metal flashing directly on cementitious or wood substrates, install a course of felt underlayment and cover with a slip sheet or install a course of polyethylene underlayment. 3. Bed flanges in thick coat of asphalt roofing cement where required for waterproof performance.
C. Install exposed sheet metal flashing and trim without excessive oil canning, buckling, and tool marks.
D. Install sheet metal flashing and trim true to line and levels indicated. Provide uniform, neat seams with minimum exposure of solder, welds, and elastomeric sealant.
E. Install sheet metal flashing and trim to fit substrates and to result in watertight performance. Verify shapes and dimensions of surfaces to be covered before fabricating sheet metal.
1. Space cleats not more than 12 inches (300 mm) apart. Anchor each cleat with two fasteners. Bend tabs over fasteners.
F. Expansion Provisions: Provide for thermal expansion of exposed flashing and trim. Space movement joints at a maximum of 10 feet (3 m) with no joints allowed within 24 inches (600 mm) of corner or intersection. Where lapped or bayonet-type expansion provisions cannot be used or would not be sufficiently watertight, form expansion joints of intermeshing hooked flanges, not less than 1 inch (25 mm) deep, filled with elastomeric sealant concealed within joints.
G. Fasteners: Use fasteners of sizes that will penetrate substrate not less than 1-1/4 inches (32 mm) for nails and not less than 3/4 inch (19 mm) for wood screws.
1. Galvanized or Prepainted, Metallic-Coated Steel: Use stainless-steel fasteners.
H. Seal joints with elastomeric sealant as required for watertight construction.
1. Where sealant-filled joints are used, embed hooked flanges of joint members not less than 1 inch (25 mm) into sealant. Form joints to completely conceal sealant. When ambient temperature at time of installation is moderate, between 40 and 70 deg F (4 and 21 deg C), set joint members for 50 percent movement either way. Adjust setting proportionately for installation at higher ambient temperatures. Do not install sealant-type joints at temperatures below 40 deg F (4 deg C). 2. Prepare joints and apply sealants to comply with requirements in Division 7 Section "Joint Sealants."
BC&A SHEET METAL FLASHING AND TRIM JVWCD PAGE 07620-9 CENTRAL PIPELINE PROJECT I. Soldered Joints: Clean surfaces to be soldered, removing oils and foreign matter. Pretin edges of sheets to be soldered to a width of 1-1/2 inches (38 mm) except where pretinned surface would show in finished Work.
1. Do not solder prepainted, metallic-coated steel sheet. 2. Pretinning is not required for lead. 3. Where surfaces to be soldered are lead coated, do not tin edges, but wire brush lead coating before soldering. 4. Do not use open-flame torches for soldering. Heat surfaces to receive solder and flow solder into joints. Fill joints completely. Completely remove flux and spatter from exposed surfaces.
3.3 ROOF DRAINAGE SYSTEM INSTALLATION
A. General: Install sheet metal roof drainage items to produce complete roof drainage system according to SMACNA recommendations and as indicated. Coordinate installation of roof perimeter flashing with installation of roof drainage system.
B. Hanging Gutters: Join sections with riveted and soldered joints or with lapped joints sealed with elastomeric sealant. Provide for thermal expansion. Attach gutters at eave or fascia to firmly anchored gutter brackets spaced not more than 36 inches (900 mm) apart. Provide end closures and seal watertight with sealant. Slope to downspouts.
1. Fasten gutter spacers to front and back of gutter. 2. Loosely lock straps to front gutter bead and anchor to roof deck. 3. Anchor and loosely lock back edge of gutter to continuous eave or apron flashing. 4. Anchor back of gutter that extends onto roof deck with cleats spaced not more than 24 inches (600 mm) apart. 5. Anchor gutter with spikes and ferrules spaced not more than 24 inches (600 mm) apart. 6. Install gutter with expansion joints at locations indicated but not exceeding 50 feet (15.24 m) apart. Install expansion joint caps. 7. Install continuous gutter screens on gutters with noncorrosive fasteners, hinged to swing open for cleaning gutters.
C. Downspouts: Join sections with 1-1/2-inch (38-mm) telescoping joints. Provide fasteners designed to hold downspouts securely 1 inch (25 mm) away from walls; locate fasteners at top and bottom and at approximately 60 inches (1500 mm) o.c. in between.
1. Provide elbows at base of downspout to direct water away from building or connect downspouts to underground drainage system indicated.
3.4 ROOF FLASHING INSTALLATION
A. General: Install sheet metal roof flashing and trim to comply with performance requirements, sheet metal manufacturer's written installation instructions, and SMACNA's "Architectural Sheet Metal Manual." Provide concealed fasteners where possible, set units true to line, and level as indicated. Install work with laps, joints, and seams that will be permanently watertight.
BC&A SHEET METAL FLASHING AND TRIM JVWCD PAGE 07620-10 CENTRAL PIPELINE PROJECT
B. Roof Edge Flashing: Anchor to resist uplift and outward forces according to recommendations in FMG Loss Prevention Data Sheet 1-49 for specified wind zone and as indicated.
1. Interlock bottom edge of roof edge flashing with continuous cleats anchored to substrate at 16-inch (400-mm) centers.
C. Copings: Anchor to resist uplift and outward forces according to recommendations in FMG Loss Prevention Data Sheet 1-49 for specified wind zone and as indicated.
1. Interlock exterior bottom edge of coping with continuous cleats anchored to substrate at 16-inch (400-mm) centers. 2. Anchor interior leg of coping with screw fasteners and washers at 18-inch (450-mm) centers.
D. Pipe or Post Counterflashing: Install counterflashing umbrella with close-fitting collar with top edge flared for elastomeric sealant, extending a minimum of 4 inches (100 mm) over base flashing. Install stainless-steel draw band and tighten.
E. Counterflashing: Coordinate installation of counterflashing with installation of base flashing. Insert counterflashing in reglets or receivers and fit tightly to base flashing. Extend counterflashing 4 inches (100 mm) over base flashing. Lap counterflashing joints a minimum of 4 inches (100 mm) and bed with elastomeric sealant.
1. Secure in a waterproof manner by means of snap-in installation and sealant.
F. Roof-Penetration Flashing: Coordinate installation of roof-penetration flashing with installation of roofing and other items penetrating roof. Install flashing as follows:
1. Seal with elastomeric sealant and clamp flashing to pipes penetrating roof except for lead flashing on vent piping.
3.5 WALL FLASHING INSTALLATION
A. General: Install sheet metal wall flashing to intercept and exclude penetrating moisture according to SMACNA recommendations and as indicated. Coordinate installation of wall flashing with installation of wall-opening components such as windows, doors, and louvers.
B. Through-Wall Flashing: Installation of formed through-wall flashing is specified in Division 4 Section "Unit Masonry Assemblies."
C. Reglets: Installation of reglets is specified in Division 3 Section "Cast-in-Place Concrete and in 4 Section "Unit Masonry Assemblies."
D. Openings Flashing in Frame Construction: Install continuous head, sill, jamb, and similar flashings to extend 4 inches (100 mm) beyond wall openings.
BC&A SHEET METAL FLASHING AND TRIM JVWCD PAGE 07620-11 CENTRAL PIPELINE PROJECT
3.6 MISCELLANEOUS FLASHING INSTALLATION
A. Equipment Support Flashing: Coordinate installation of equipment support flashing with installation of roofing and equipment. Weld or seal flashing with elastomeric sealant to equipment support member.
3.7 CLEANING AND PROTECTION
A. Clean exposed metal surfaces of substances that interfere with uniform oxidation and weathering.
B. Clean and neutralize flux materials. Clean off excess solder and sealants.
C. Remove temporary protective coverings and strippable films as sheet metal flashing and trim are installed. On completion of installation, clean finished surfaces, including removing unused fasteners, metal filings, pop rivet stems, and pieces of flashing. Maintain in a clean condition during construction.
D. Replace sheet metal flashing and trim that have been damaged or that have deteriorated beyond successful repair by finish touchup or similar minor repair procedures.
END OF SECTION
BC&A SHEET METAL FLASHING AND TRIM JVWCD PAGE 07620-12 CENTRAL PIPELINE PROJECT SECTION 07720 ROOF ACCESSORIES
PART 1 -- GENERAL
1.1 THE REQUIREMENT
A. The CONTRACTOR shall provide all roof accessories and appurtenant work as needed to construct a built-up roof, complete and in place, in accordance with the Contract Documents.
1.2 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS
A. Trade Standards: National Roofing Contractors Association (NRCA).
B. Manufacturer's Standards: In addition to the standards listed above, roof accessories and installation shall be in accordance with the manufacturer's published recommendations and specifications.
1.3 CONTRACTOR SUBMITTALS
A. Furnish submittals shall be in accordance with Section 01300 - Contractor Submittals.
B. Shop Drawings: Submit for all roof hatches and prefabricated curbs prior to fabrication.
C. Product Information: The manufacturer's specifications, literature, and published installation instructions for each accessory, product, or system shall be submitted to the ENGINEER.
1.4 PRODUCT DELIVERY, STORAGE, AND HANDLING
A. Delivery of Materials: Manufactured materials shall be delivered in original, unbroken, packages, containers, or bundles bearing the name of the manufacturer.
B. Storage: All materials shall be carefully stored on wood blocking in an area that is protected from the elements. Storage shall be in a manner that will prevent damage or marring of finish.
PART 2 -- PRODUCTS
2.1 ROOF HATCHES
A. Design: Roof hatches (scuttles, equipment hatches) shall be constructed of aluminum, unless otherwise indicated, and shall be provided with stainless steel hardware, including padlocking hardware inside and neoprene gaskets and seals. Roof hatches shall be of the type and size indicated.
1. Roof hatch, single leaf, 4-ft by 4-ft: Bilco F-50, Babcock-Davis 6-704, or equal.
BC&A ROOF ACCESSORIES JVWCD PAGE 07720-1 CENTRAL PIPELINE PROJECT B. Manufacturers, or Equal:
1. Babcock-Davis Hatchways, Inc. 2. Bilco Company
2.2 PREFABRICATED CURBS
A. Design: Opening dimensions shall be coordinated with skylight penetrations, duct penetrations, and roof-mounted equipment sizes. Heights shall be as required to place top of curb not less than 8 inches above top of insulation unless otherwise indicated. The top edge of the curb shall be a level surface for installation, connection, and/or mounting of equipment, skylights, etc. Sides of curbs shall have heights adjusted per job and field conditions and roof stoops. Base flange shall be not less than 3-1/2 inches wide. Curbs shall be fabricated of 14 gage or thicker aluminum with continuously welded corners and shall be provided with pressure preservative treated, kiln dried, fire-treated wood nailer at top.
B. Manufacturers, or Equal:
1. Pate Company 2. S & L Manufacturing Company 3. Thybar Corporation.
2.3 LADDER-UP DEVICE
A. Roof hatch ladder-up device (extendable pole) shall be "Model 2, Ladder-Up Safety Post" of hot-dipped galvanized steel as manufactured by Bilco, Co., or equal.
PART 3 -- EXECUTION
3.1 GENERAL
A. The installation shall conform to applicable codes and the manufacturer's published or written recommendations, specifications, and published installation instructions for the type of work being performed. The construction shall be coordinated with the work of other trades.
B. Unless otherwise indicated, roof openings, roof-mounted equipment, duct openings, and skylights shall be provided with a prefabricated curb unless the equipment above the roof opening is supplied with its own curb which extends to 8 inches or higher beyond the top of the roof insulation. The prefabricated curb may be part of the equipment item.
C. Roof hatches with ladders shall be provided with a ladder-up device.
3.2 INSTALLATION
A. Roof hatches shall be installed over prepared openings with their own curbs or prefabricated curbs, and shall be fastened to roof deck in accordance with the manufacturer's printed directions. Lifting mechanisms and accessories shall be adjusted
BC&A ROOF ACCESSORIES JVWCD PAGE 07720-2 CENTRAL PIPELINE PROJECT to insure proper operation. Abraded prime and finish coat surfaces shall be touched-up after completion of installation with the same type finish and the same dry-film thickness.
1. Roof Hatches: Dissimilar metals shall be properly isolated. Thermal movement, up to 100 degrees F change, shall be accommodated without distress in assembly of fasteners.
B. Protective Coating: All roof accessories shall be coated in accordance with Section 09900 – Painting, to match the roofing color unless directed otherwise by the ENGINEER. Primer coats shall be compatible with finish coats.
- END OF SECTION -
BC&A ROOF ACCESSORIES JVWCD PAGE 07720-3 CENTRAL PIPELINE PROJECT
SECTION 07841 THROUGH-PENETRATION FIRESTOP SYSTEMS
PART 1 – GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section includes through-penetration firestop systems for penetrations through fire-resistance-rated constructions, including both empty openings and openings containing penetrating items.
1. The Work of this section shall include, but not be limited to, all clips and other restraining devices necessary for holding fire protection material in place and other items necessary for a complete and integral installation thru out the entire perimeter and other penetrations.
B. Related Sections include the following:
1. Division 1 Section "LEED Requirements" for LEED certification targets, related LEED requirements, recycled content minima, other LEED criteria and constraints. 2. Information attached for reference, including LEED Checklist for Project building(s), indicating which LEED credits are targeted for attainment. 3. LEED reference documents, not attached but available for use, including the “LEED- New Construction v.2.2 Rating System,” explaining requirements for each prerequisite and credit, and the “LEED-New Construction v2.2 Reference Guide,” detailing requirements and documentation options for application for each prerequisite and credit. 4. Division 7 Section "Fire-Resistive Joint Systems." 5. Division 15 Sections specifying duct and piping penetrations. 6. Division 16 Sections specifying cable and conduit penetrations.
1.3 PERFORMANCE REQUIREMENTS
A. General: For penetrations through the following fire-resistance-rated constructions, including both empty openings and openings containing penetrating items, provide through-penetration firestop systems that are produced and installed to resist spread of fire according to requirements indicated, resist passage of smoke and other gases, and maintain original fire-resistance rating of construction penetrated.
1. Fire-resistance-rated walls including fire walls, fire partitions, fire barriers, and smoke barriers. 2. Fire-resistance-rated horizontal assemblies including floor/ceiling assemblies and ceiling membranes of roof/ceiling assemblies.
BC&A THROUGH-PENETRATION FIRESTOP SYSTEMS JVWCD PAGE 07841-1 CENTRAL PIPELINE PROJECT B. Rated Systems: Provide through-penetration firestop systems with the following ratings determined per ASTM E 814 or UL 1479:
1. F-Rated Systems: Provide through-penetration firestop systems with F-ratings indicated, but not less than that equaling or exceeding fire-resistance rating of constructions penetrated. 2. T-Rated Systems: For the following conditions, provide through-penetration firestop systems with T-ratings indicated, as well as F-ratings, where systems protect penetrating items exposed to potential contact with adjacent materials in occupiable floor areas: a. Penetrations located outside wall cavities. b. Penetrations located outside fire-resistance-rated shaft enclosures. 3. L-Rated Systems: Where through-penetration firestop systems are indicated in smoke barriers, provide through-penetration firestop systems with L-ratings of not more than 3.0 cfm/sq. ft (0.01524cu. m/s x sq. m) at both ambient temperatures and 400 deg F (204 deg C).
C. For through-penetration firestop systems exposed to view, traffic, moisture, and physical damage, provide products that, after curing, do not deteriorate when exposed to these conditions both during and after construction.
1. For piping penetrations for plumbing and wet-pipe sprinkler systems, provide moisture-resistant through-penetration firestop systems. 2. For floor penetrations with annular spaces exceeding 4 inches (100 mm) in width and exposed to possible loading and traffic, provide firestop systems capable of supporting floor loads involved, either by installing floor plates or by other means. 3. For penetrations involving insulated piping, provide through-penetration firestop systems not requiring removal of insulation.
D. For through-penetration firestop systems exposed to view, provide products with flame-spread and smoke-developed indexes of less than 25 and 450, respectively, as determined per ASTM E 84.
1.4 SUBMITTALS
A. Product Data: For each type of product indicated.
B. LEED Submittal:
1. Product Data for Credit EQ 4.1: For penetration firestopping, including printed statement of VOC content and chemical components.
C. Shop Drawings: For each through-penetration firestop system, show each type of construction condition penetrated, relationships to adjoining construction, and type of penetrating item. Include firestop design designation of qualified testing and inspecting agency that evidences compliance with requirements for each condition indicated.
1. Submit documentation, including illustrations, from a qualified testing and inspecting agency that is applicable to each through-penetration firestop system configuration for construction and penetrating items.
BC&A THROUGH-PENETRATION FIRESTOP SYSTEMS JVWCD PAGE 07841-2 CENTRAL PIPELINE PROJECT D. Through-Penetration Firestop System Schedule: Indicate locations of each through-penetration firestop system, along with the following information:
1. Types of penetrating items. 2. Types of constructions penetrated, including fire-resistance ratings and, where applicable, thicknesses of construction penetrated. 3. Through-penetration firestop systems for each location identified by firestop design designation of qualified testing and inspecting agency.
E. Qualification Data: For Installer.
F. Product Test Reports: From a qualified testing agency indicating through-penetration firestop system complies with requirements, based on comprehensive testing of current products. 1.5 QUALITY ASSURANCE
A. Installer Qualifications: A firm that has been approved by FMG according to FMG 4991, "Approval of Firestop Contractors."
B. Installation Responsibility: Assign installation of through-penetration firestop systems and fire-resistive joint systems in Project to a single qualified installer.
C. Source Limitations: Obtain through-penetration firestop systems, for each kind of penetration and construction condition indicated, through one source from a single manufacturer.
D. Fire-Test-Response Characteristics: Provide through-penetration firestop systems that comply with the following requirements and those specified in Part 1 "Performance Requirements" Article:
1. Firestopping tests are performed by a qualified testing and inspecting agency. A qualified testing and inspecting agency is UL or another agency performing testing and follow-up inspection services for firestop systems acceptable to authorities having jurisdiction. 2. Through-penetration firestop systems are identical to those tested per testing standard referenced in "Part 1 Performance Requirements" Article. Provide rated systems complying with the following requirements: a. Through-penetration firestop system products bear classification marking of qualified testing and inspecting agency. b. Through-penetration firestop systems correspond to those indicated by reference to through-penetration firestop system designations listed by the following: 1) UL in its "Fire Resistance Directory."
E. Preinstallation Conference: Conduct conference at Project site to comply with requirements in Division 1 Section "Project Management and Coordination."
1.6 DELIVERY, STORAGE, AND HANDLING
A. Deliver through-penetration firestop system products to Project site in original, unopened containers or packages with intact and legible manufacturers' labels identifying product and
BC&A THROUGH-PENETRATION FIRESTOP SYSTEMS JVWCD PAGE 07841-3 CENTRAL PIPELINE PROJECT manufacturer, date of manufacture, lot number, shelf life if applicable, qualified testing and inspecting agency's classification marking applicable to Project, curing time, and mixing instructions for multicomponent materials.
B. Store and handle materials for through-penetration firestop systems to prevent their deterioration or damage due to moisture, temperature changes, contaminants, or other causes.
1.7 PROJECT CONDITIONS
A. Environmental Limitations: Do not install through-penetration firestop systems when ambient or substrate temperatures are outside limits permitted by through-penetration firestop system manufacturers or when substrates are wet due to rain, frost, condensation, or other causes.
B. Ventilate through-penetration firestop systems per manufacturer's written instructions by natural means or, where this is inadequate, forced-air circulation.
1.8 COORDINATION
A. Coordinate construction of openings and penetrating items to ensure that through-penetration firestop systems are installed according to specified requirements.
B. Coordinate sizing of sleeves, openings, core-drilled holes, or cut openings to accommodate through-penetration firestop systems.
C. Notify Owner's inspecting agency at least seven days in advance of through-penetration firestop system installations; confirm dates and times on days preceding each series of installations.
D. Do not cover up through-penetration firestop system installations that will become concealed behind other construction until each installation has been examined by Owner's inspecting agency and building inspector, if required by authorities having jurisdiction.
PART 2 – PRODUCTS
2.1 MANUFACTURERS
A. Available Products: Subject to compliance with requirements, through-penetration firestop systems that may be incorporated into the Work include, but are not limited to, those systems indicated that are produced by one of the following manufacturers:
1. Grace, W. R. & Co. - Conn. 2. Hilti, Inc. 3. Nelson Firestop Products. 4. 3M; Fire Protection Products Division. 5. Tremco; Sealant/Weatherproofing Division.
BC&A THROUGH-PENETRATION FIRESTOP SYSTEMS JVWCD PAGE 07841-4 CENTRAL PIPELINE PROJECT 2.2 FIRESTOPPING, GENERAL
A. Compatibility: Provide through-penetration firestop systems that are compatible with one another; with the substrates forming openings; and with the items, if any, penetrating through-penetration firestop systems, under conditions of service and application, as demonstrated by through-penetration firestop system manufacturer based on testing and field experience.
B. VOC Content: Provide penetration firestopping that complies with the following limits for VOC content when calculated according to 40 CFR 59, Subpart D (EPA Method 24):
1. Architectural Sealants: 250 g/L. 2. Sealant Primers for Nonporous Substrates: 250 g/L. 3. Sealant Primers for Porous Substrates: 775 g/L.
C. Accessories: Provide components for each through-penetration firestop system that are needed to install fill materials and to comply with Part 1 "Performance Requirements" Article. Use only components specified by through-penetration firestop system manufacturer and approved by qualified testing and inspecting agency for firestop systems indicated. Accessories include, but are not limited to, the following items:
1. Permanent forming/damming/backing materials, including the following: a. Slag-/rock-wool-fiber insulation. b. Sealants used in combination with other forming/damming/backing materials to prevent leakage of fill materials in liquid state. c. Fire-rated form board. d. Fillers for sealants. 2. Temporary forming materials. 3. Substrate primers. 4. Collars. 5. Steel sleeves.
2.3 FILL MATERIALS
A. General: Provide through-penetration firestop systems containing the types of fill materials indicated. Fill materials are those referred to in directories of referenced testing and inspecting agencies as "fill," "void," or "cavity" materials.
B. Cast-in-Place Firestop Devices: Factory-assembled devices for use in cast-in-place concrete floors and consisting of an outer metallic sleeve lined with an intumescent strip, a radial extended flange attached to one end of the sleeve for fastening to concrete formwork, and a neoprene gasket.
C. Latex Sealants: Single-component latex formulations that after cure do not re-emulsify during exposure to moisture.
D. Firestop Devices: Factory-assembled collars formed from galvanized steel and lined with intumescent material sized to fit specific diameter of penetrant.
BC&A THROUGH-PENETRATION FIRESTOP SYSTEMS JVWCD PAGE 07841-5 CENTRAL PIPELINE PROJECT E. Mortars: Prepackaged dry mixes consisting of a blend of inorganic binders, hydraulic cement, fillers, and lightweight aggregate formulated for mixing with water at Project site to form a nonshrinking, homogeneous mortar.
F. Pillows/Bags: Reusable heat-expanding pillows/bags consisting of glass-fiber cloth cases filled with a combination of mineral-fiber, water-insoluble expansion agents, and fire-retardant additives.
G. Silicone Foams: Multicomponent, silicone-based liquid elastomers that, when mixed, expand and cure in place to produce a flexible, nonshrinking foam.
H. Silicone Sealants: Single-component, silicone-based, neutral-curing elastomeric sealants of grade indicated below:
1. Grade: Pourable (self-leveling) formulation for openings in floors and other horizontal surfaces, and nonsag formulation for openings in vertical and other surfaces requiring a nonslumping, gunnable sealant, unless indicated firestop system limits use to nonsag grade for both opening conditions.
2.4 MIXING
A. For those products requiring mixing before application, comply with through-penetration firestop system manufacturer's written instructions for accurate proportioning of materials, water (if required), type of mixing equipment, selection of mixer speeds, mixing containers, mixing time, and other items or procedures needed to produce products of uniform quality with optimum performance characteristics for application indicated.
PART 3 – EXECUTION
3.1 EXAMINATION
A. Examine substrates and conditions, with Installer present, for compliance with requirements for opening configurations, penetrating items, substrates, and other conditions affecting performance of Work.
1. Proceed with installation only after unsatisfactory conditions have been corrected.
3.2 PREPARATION
A. Surface Cleaning: Clean out openings immediately before installing through-penetration firestop systems to comply with firestop system manufacturer's written instructions and with the following requirements:
1. Remove from surfaces of opening substrates and from penetrating items foreign materials that could interfere with adhesion of through-penetration firestop systems. 2. Clean opening substrates and penetrating items to produce clean, sound surfaces capable of developing optimum bond with through-penetration firestop systems. Remove loose particles remaining from cleaning operation. 3. Remove laitance and form-release agents from concrete.
BC&A THROUGH-PENETRATION FIRESTOP SYSTEMS JVWCD PAGE 07841-6 CENTRAL PIPELINE PROJECT B. Priming: Prime substrates where recommended in writing by through-penetration firestop system manufacturer using that manufacturer's recommended products and methods. Confine primers to areas of bond; do not allow spillage and migration onto exposed surfaces.
C. Masking Tape: Use masking tape to prevent through-penetration firestop systems from contacting adjoining surfaces that will remain exposed on completion of Work and that would otherwise be permanently stained or damaged by such contact or by cleaning methods used to remove smears from firestop system materials. Remove tape as soon as possible without disturbing firestop system's seal with substrates.
3.3 THROUGH-PENETRATION FIRESTOP SYSTEM INSTALLATION
A. General: Install through-penetration firestop systems to comply with Part 1 "Performance Requirements" Article and with firestop system manufacturer's written installation instructions and published drawings for products and applications indicated.
B. Install forming/damming/backing materials and other accessories of types required to support fill materials during their application and in the position needed to produce cross-sectional shapes and depths required to achieve fire ratings indicated.
1. After installing fill materials and allowing them to fully cure, remove combustible forming materials and other accessories not indicated as permanent components of firestop systems.
C. Install fill materials for firestop systems by proven techniques to produce the following results:
1. Fill voids and cavities formed by openings, forming materials, accessories, and penetrating items as required to achieve fire-resistance ratings indicated. 2. Apply materials so they contact and adhere to substrates formed by openings and penetrating items. 3. For fill materials that will remain exposed after completing Work, finish to produce smooth, uniform surfaces that are flush with adjoining finishes.
3.4 IDENTIFICATION
A. Identify through-penetration firestop systems with preprinted metal or plastic labels. Attach labels permanently to surfaces adjacent to and within 6 inches (150 mm) of edge of the firestop systems so that labels will be visible to anyone seeking to remove penetrating items or firestop systems. Use mechanical fasteners for metal labels. For plastic labels, use self-adhering type with adhesives capable of permanently bonding labels to surfaces on which labels are placed and, in combination with label material, will result in partial destruction of label if removal is attempted. Include the following information on labels:
1. The words "Warning - Through-Penetration Firestop System - Do Not Disturb. Notify Building Management of Any Damage." 2. Contractor's name, address, and phone number. 3. Through-penetration firestop system designation of applicable testing and inspecting agency. 4. Date of installation.
BC&A THROUGH-PENETRATION FIRESTOP SYSTEMS JVWCD PAGE 07841-7 CENTRAL PIPELINE PROJECT 5. Through-penetration firestop system manufacturer's name. 6. Installer's name.
3.5 FIELD QUALITY CONTROL
A. Inspecting Agency: Owner will engage a qualified, independent inspecting agency to inspect through-penetration firestops. Independent inspecting agency shall comply with ASTM E 2174 requirements including those related to qualifications, conducting inspections, and preparing test reports.
B. Where deficiencies are found, repair or replace through-penetration firestop systems so they comply with requirements.
C. Proceed with enclosing through-penetration firestop systems with other construction only after inspection reports are issued and firestop installations comply with requirements.
3.6 CLEANING AND PROTECTING
A. Clean off excess fill materials adjacent to openings as Work progresses by methods and with cleaning materials that are approved in writing by through-penetration firestop system manufacturers and that do not damage materials in which openings occur.
B. Provide final protection and maintain conditions during and after installation that ensure that through-penetration firestop systems are without damage or deterioration at time of Substantial Completion. If, despite such protection, damage or deterioration occurs, cut out and remove damaged or deteriorated through-penetration firestop systems immediately and install new materials to produce systems complying with specified requirements.
END OF SECTION
BC&A THROUGH-PENETRATION FIRESTOP SYSTEMS JVWCD PAGE 07841-8 CENTRAL PIPELINE PROJECT SECTION 07900 JOINT SEALANTS
PART 1 - GENERAL
1.1 SUMMARY
A. Section includes sealant work associated with joints between similar and dissimilar materials in the Work.
B. Work included consists of, but is not necessarily limited to the following: 1. Sealing all joints which would otherwise permit penetration of moisture, unless sealing work is specifically required under other sections. a. Flashing reglets and retainers. b. Exterior wall joints. c. Flooring joints. d. Isolation joints. e. Joints between paving and sidewalks and building. f. Concrete control and expansion joints, exterior and interior. g. Joints at penetrations of walls, floors, and decks by piping and other services and equipment. h. Exterior and interior perimeters of exterior and interior door and window frames, louvers, grilles, etc. i. Thresholds at exterior doors. j. Sealing of plumbing fixtures to floor or wall. k. Other joints where calking, sealant, or compressible sealant is indicated.
1.2 REFERENCES
A. ASTM International (ASTM) standards, most recent editions:
ASTM C920 Standard Specification for Elastomeric Joint Sealants
ASTM C1087 Standard Test Method for Determining Compatibility of Liquid-Applied Sealants with Accessories Used in Structural Glazing Systems
ASTM C1193 Standard Guide for Use of Joint Sealants
ASTM C1247 Standard Test Method for Durability of Sealants Exposed to Continuous Immersion in Liquids
B. Federal Specification (FS), most recent editions:
TT-S-001543A Sealing Compound: Silicone Rubber Base (for Caulking, Sealing, and Glazing in Buildings and Other Structures)
TT-S-00230C Sealing Compound: Elastomeric Type, Single Component (For Calking, Sealing, and Glazing in Buildings and Other Structures)
BC&A JVWCD JOINT SEALANTS CENTRAL PIPELINE PROJECT PAGE 07900 - 1 TT-S-00227E Sealing Compound: Elastomeric Type, Multi-Component (for Caulking, Sealing, and Glazing in Buildings and Other Structures)
C. Underwriters Laboratories Inc. (UL):
Building Materials Directory
1.3 DEFINITIONS
A. Words "calk," "sealant," and "calking" mean sealant Work.
B. "Interior wet areas" mean toilets, showers, sinks, and similar areas.
C. "Applicator" means the individual actually on site performing the installation.
D. "Vertical" means any surface with a slope greater than 1.5 horizontal to 1.0 vertical.
1.4 QUALITY ASSURANCE
A. Qualifications: 1. Sealant applicator shall have a minimum of five years of experience on projects with similar scope.
B. Mock-ups: 1. Before calking work is started, a sample of each type of joint shall be calked where directed by ENGINEER. The approved samples shall show the workmanship, bond, and color of calking materials as specified or selected for the Work and shall be the minimum standard of quality on the entire Project.
C. Preconstruction compatibility and adhesion testing: 1. Submit to joint-sealant manufacturers, for testing indicated below, samples of materials that will contact of affect joint sealants. a. Use ASTM C1087 to determine whether priming and other specific joint preparation techniques are required to obtain rapid, optimum adhesion of joint sealants to joint substrates. b. Submit not fewer than eight pieces of each type of material, including joint substrates, shims, sealant backings, secondary seals, and miscellaneous materials. c. Schedule sufficient time for testing and analyzing results to prevent delaying the Work. d. For materials failing tests, obtain sealant manufacturer’s written instructions for corrective measures including use of specially formulated primers. e. Testing will not be required if sealant manufacturers submit joint preparation data that are based on previous testing of current sealant products for adhesion to, and compatibility with, joint substrates and other materials matching those submitted.
BC&A JVWCD JOINT SEALANTS CENTRAL PIPELINE PROJECT PAGE 07900 - 2 D. Preconstruction field-adhesion testing: Before installing elastomeric sealants, field test their adhesion to joint substrates found in the Work as follows: 1. Locate test joints where indicated in the Work or, if not indicated, as directed by the ENGINEER. 2. Conduct tests for each application indicated below: a. Each type of elastomeric sealant and joint substrate indicated. 3. Notify ENGINEER a minimum of 7 days in advance of dates and times when test joints will be evaluated. 4. Test method: Test joint sealants according to Method A, Field-Applied Sealant Joint Hand Pull Tab, in Appendix X1 of ASTM C1193. 5. Report whether sealant in joint connected to pulled-out portion failed to adhere to joint substrates or tore cohesively. Include data on pull distance used to test each type of product and joint substrate. For sealants that fail adhesively, retest until satisfactory adhesion is obtained. 6. Evaluation of preconstruction field-adhesion test results: Sealants not evidencing adhesive failure from testing, in absence of other indications of noncompliance with requirements, will be considered satisfactory. Do not use sealants that fail to adhere to joint substrates during testing.
1.5 SUBMITTALS
A. Comply with Section 01300.
B. Product Data 1. Letter of certification that products submitted meet requirements of standards referenced. 2. Manufacturer's installation instructions. 3. Manufacturer's recommendations for joint cleaner, primer, backer rod, tooling, and bond breaker. 4. Applicator qualifications. 5. Warranty. 6. Certification from sealant manufacturer stating that product being used is recommended for and is best suited for joint in which it is being applied.
C. Field Samples 1. Cured sample of each color for ENGINEER's color selection. Color chart not acceptable.
D. Preconstruction field test reports: Indicate which sealants and joint preparation methods resulted in optimum adhesion to joint substrates based on preconstruction testing specified in below in QUALITY ASSURANCE.
E. Product test reports: Based on comprehensive testing of product formulations performed by a qualified testing agency, indicating that sealants comply with requirements.
F. Warranties: Special warranties specified in this Section.
1.6 DELIVERY, STORAGE, AND HANDLING
A. Deliver products to site, store and protect products under provisions of Section 01600.
BC&A JVWCD JOINT SEALANTS CENTRAL PIPELINE PROJECT PAGE 07900 - 3 B. Deliver material in manufacturer's original unopened containers with labels intact. Labels shall indicate contents and expiration date of material.
C. Store all materials off the ground and protect from rain, freezing, or excessive heat until ready for use.
D. Condition the specified products before use as recommended by the manufacturer.
1.7 ENVIRONMENTAL REQUIREMENTS
A. Schedule Work to be performed when temperature and humidity are as recommended by the sealant manufacturer during and after installation until products are fully cured.
1.8 WARRANTY
A. Material and Labor Warranty: 1. Sealant work shall be free of defects for a period of 5 years from date of final acceptance. 2. Failure of watertightness constitutes defect. 3. Remove any defective work and/or materials and replace with new materials. 4. Warranty must be sighed jointly by applicator and sealant manufacturer.
B. Special installer’s warranty: 1. Installer’s standard form in which installer agrees to repair or replace elastomeric joint sealants that do not comply with performance and other requirements specified herein within specified warranty period. a. Warranty period: Five years from date of final acceptance. 2. Special warranties herein specified exclude deterioration or failure of elastomeric joint sealants from the following: a. Movement of the structure resulting in stresses on the sealant exceeding sealant manufacturer’s written specifications for sealant elongation and compression caused by structural settlement or errors attributable to design. b. Disintegration of joint substrates from natural causes exceeding design specifications. c. Mechanical damage by individuals, tools, or other outside agents. d. Changes in sealant appearance caused by accumulation of dirt or other atmospheric contaminants.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. Subject to compliance with the Contract Documents, the following Manufacturers are acceptable: 1. Polyurethane sealants. a. MAMECO International. b. Sika Chemical Corporation. c. Pecora. d. PSI Polymeric Systems, Inc.
BC&A JVWCD JOINT SEALANTS CENTRAL PIPELINE PROJECT PAGE 07900 - 4 e. Sonneborn – Rexnord. f. Tremco g. ENGINEER approved equal. 2. Silicone sealants: a. General Electric. b. Dow Corning Corporation. c. Tremco d. ENGINEER approved equal. 3. Fire Resistant Sealant: a. Dow Corning. b. 3M Corporation. c. ENGINEER approved equal.
2.2 MATERIALS
A. Sealants – General: 1. Provide joint sealants, backings, and other related materials that are compatible with one another and with joint substrates under conditions of service and application, as demonstrated by sealant manufacturer, based on testing and field experience. 2. Where compound is exposed to view in finished Work, provide colors matching materials being sealed. 3. Where compound is not exposed to view in finished Work, provide manufacturer's color with best performance. 4. Provide non sagging sealant for vertical and overhead joints. 5. Sealants for horizontal joints: a. Self-leveling pedestrian/traffic grade. 6. Suitability for immersion in liquids: Where elastomeric sealants are indicated for submerged use, provide products that have undergone testing according to ASTM C1247 and qualify for the length of exposure indicated by reference to ASTM C920 for Classes 1 or 2. Liquid used for testing sealants is chlorinated potable water, unless otherwise noted.
B. Polyurethane Sealant: 1. One or two components. 2. Meet ASTM C920; F.S. TT-S-00230C, Type I or Type II, Class A, or TT-S-00227E, Type I or Type II, Class A. a. Sika Sikaflex-1A, Sikaflex-2C. b. Pecora Dynatrol I, Dynatrol II, Urexpan NR-200 or NR-201. c. PSI PSI-270. d. Sonneborn Sonolastic NP-1, NP-II, SL-1. e. Tremco Vulkem 116, 227, 45, 245.
C. Silicone Sealant: 1. One component. 2. Meet F.S. TT-S-001543A, Class A: a. General Electric Silpruf, Silglaze, Sanitary SCS 1700 sealant. b. Dow Corning 790, 795, 786. c. Tremco Spectrem.
BC&A JVWCD JOINT SEALANTS CENTRAL PIPELINE PROJECT PAGE 07900 - 5 D. Bond breaker tape: Polyethylene tape of other plastic tape recommended by sealant manufacturer for preventing sealant from adhering to rigid, inflexible joint-filler materials or joint surfaces at back of joint surfaces of joint where such adhesion would result in sealant failure. Provide self-adhesive tape where applicable.
E. Joint Cleaner, Primer, Bond Breaker: 1. As recommended by sealant manufacturer.
F. Sealant Backer Rod: Closed cell polyethylene, polyethylene jacketed polyurethane foam, or other flexible, non absorbent, non bituminous material recommended by sealant manufacturer to: 1. Control joint depth 2. Break bond of sealant oat bottom of joint 3. Provide proper shape of sealant bead.
G. Fire-Resistant Sealant: 1. One or two component. 2. Furnish sealant which has been tested for use as a fire and smoke penetration seal. a. Dow Corning Firestop. b. 3M Corporation Fire Dam 150. 3. UL approved for intended use.
PART 3 - EXECUTION
3.1 PREPARATION
A. Before using any sealant, investigate its compatibility with adjacent joint surfaces, fillers, and other materials in the joint system.
B. Use only compatible materials.
C. Clean and prime joint surfaces in accordance with manufacturer's instructions. 1. Limit application to surfaces to receive sealant. 2. Mask off adjacent surfaces.
D. Commencing sealant installation constitutes acceptance of joints and surfaces.
3.2 INSTALLATION
A. Install products in accordance with manufacturer's instructions.
B. Where finish coating or covering is to be applied to surface, wait until such coating or covering has been applied before installing sealant; e.g., paint, wall covering, glazed coatings.
C. Make all joints water and air tight.
D. Make depth of sealing compounds not more than one-half width of joint, but in no case less than 1/4 inch nor more than 5/8 inch.
BC&A JVWCD JOINT SEALANTS CENTRAL PIPELINE PROJECT PAGE 07900 - 6 E. Provide correctly sized backer rod in all joints to proper depth
F. Apply bond breaker where required.
G. Tool sealants using sufficient pressure to fill all voids.
H. Upon completion, leave sealant with smooth even neat finish.
3.3 CLEANING
A. Clean adjacent soiled surfaces free of sealant.
3.4 PROTECTION
A. Protect finished installation.
B. Protect sealants until fully cured.
3.5 SCHEDULES
A. Furnish sealant as indicated for the following areas: 1. Exterior areas: a. Joints in concrete and masonry: 1) Use 2-component polyurethane only. b. All other joints: 1) Single or 2-component Polyurethane or. 2) Silicone. 2. Interior wet areas: a. Joints in concrete and masonry: 1) Use 2-component polyurethane only. b. All other joints: 1) Single or 2-component Polyurethane or. 2) Silicone. 3. Interior nonwet, corrosive areas: a. Joints in concrete and masonry: 1) Use 2-component polyurethane only. b. All other joints: 1) Single or 2-component Polyurethane or. 2) Silicone. 4. Fire-rated construction: Fire-resistant sealant.
END OF SECTION
BC&A JVWCD JOINT SEALANTS CENTRAL PIPELINE PROJECT PAGE 07900 - 7
DIVISION 8 DOORS AND WINDOWS
SECTION 08110 STEEL DOORS AND FRAMES
PART 1 – GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section includes the following:
1. Steel doors. 2. Steel door frames. 3. Sidelight frames 4. Borrowed-light frames.
B. Related Sections include the following:
1. Division 1 Section "LEED Requirements" for LEED certification targets, related LEED requirements, recycled content minima, other LEED criteria and constraints. 2. Information attached for reference, including LEED Checklist for Project building(s), indicating which LEED credits are targeted for attainment. 3. LEED reference documents, not attached but available for use, including the “LEED- New Construction v.2.2 Rating System,” explaining requirements for each prerequisite and credit, and the “LEED-New Construction v2.2 Reference Guide,” detailing requirements and documentation options for application for each prerequisite and credit. 4. Division 4 Section "Unit Masonry Assemblies" for installing anchors and grouting frames in masonry construction. 5. Division 8 Section "Flush Wood Doors" for wood doors installed in steel frames. 6. Division 8 Section "Door Hardware" for door hardware and weather stripping. 7. Division 8 Section "Glazing" for glass in glazed openings. 8. Division 9 Section "Gypsum Board Assemblies" for spot-grouting frames installed in steel-framed gypsum board partitions. 9. Division 9 Section "Painting" for field painting factory-primed doors and frames.
1.3 DEFINITIONS
A. Steel Sheet Thicknesses: Thickness dimensions, including those referenced in ANSI A250.8, are minimums as defined in referenced ASTM standards for both uncoated steel sheet and the uncoated base metal of metallic-coated steel sheets.
1.4 SUBMITTALS
A. Product Data: For each type of door and frame indicated, include door designation, type, level and model, material description, core description, construction details, label compliance, sound and fire-resistance ratings, and finishes.
BC&A STEEL DOORS AND FRAMES JVWCD PAGE 08110-1 CENTRAL PIPELINE PROJECT B. Shop Drawings: Show the following:
1. Elevations of each door design. 2. Details of doors including vertical and horizontal edge details. 3. Frame details for each frame type including dimensioned profiles. 4. Details and locations of reinforcement and preparations for hardware. 5. Details of each different wall opening condition. 6. Details of anchorages, accessories, joints, and connections. 7. Coordination of glazing frames and stops with glass and glazing requirements.
C. Door Schedule: Use same reference designations indicated on Drawings in preparing schedule for doors and frames.
D. Oversize Construction Certificates: For door assemblies required to be fire-protection rated and exceeding size limitations of labeled assemblies.
E. Metallic Construction Certificates: For door assemblies (doors and frames) required to be of metallic coated steel for compliance with this specification section.
1.5 QUALITY ASSURANCE
A. Steel Door and Frame Standard: Comply with ANSI A 250.8, unless more stringent requirements are indicated.
B. Fire-Rated Door Assemblies: Assemblies complying with NFPA 80 that are listed and labeled by a testing and inspecting agency acceptable to authorities having jurisdiction, for fire-protection ratings indicated, based on testing according to NFPA 252.
1. Test Pressure: Test at atmospheric pressure. 2. Oversize Fire-Rated Door Assemblies: For units exceeding sizes of tested assemblies, provide certification by a testing agency acceptable to authorities having jurisdiction that doors comply with standard construction requirements for tested and labeled fire-rated door assemblies except for size.
1.6 DELIVERY, STORAGE, AND HANDLING
A. Deliver doors and frames cardboard-wrapped or crated to provide protection during transit and job storage. Provide additional protection to prevent damage to finish of factory-finished doors and frames.
B. Inspect doors and frames on delivery for damage, and notify shipper and supplier if damage is found. Minor damages may be repaired provided refinished items match new Work and are acceptable to Architect. Remove and replace damaged items that cannot be repaired as directed.
C. Store doors and frames at building site under cover. Place units on minimum 4-inch-high wood blocking. Avoid using nonvented plastic or canvas shelters that could create a humidity chamber. If door packaging becomes wet, remove cartons immediately. Provide minimum 1/4-inch spaces between stacked doors to permit air circulation.
BC&A STEEL DOORS AND FRAMES JVWCD PAGE 08110-2 CENTRAL PIPELINE PROJECT PART 2 – PRODUCTS
2.1 MANUFACTURERS
A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:
1. Steel Doors and Frames: a. Amweld Building Products, Inc. b. Ceco Door Products; a United Dominion Company. c. Curries Company. d. Kewanee Corporation (The). e. Pioneer Industries Inc. f. Republic Builders Products. g. Steelcraft; a division of Ingersoll-Rand.
2.2 MATERIALS
A. Hot-Rolled Steel Sheets: ASTM A 569/A 569M, Commercial Steel (CS), Type B; free of scale, pitting, or surface defects; pickled and oiled.
B. Cold-Rolled Steel Sheets: ASTM A 366/A 366M, Commercial Steel (CS), or ASTM A 620/A 620M, Drawing Steel (DS), Type B; stretcher-leveled standard of flatness.
C. Metallic-Coated Steel Sheets: ASTM A 653/A 653M, Commercial Steel (CS), Type B, with an A40 zinc-iron-alloy (galvannealed) coating; stretcher-leveled standard of flatness.
D. Electrolytic Zinc-Coated Steel Sheet: ASTM A 591/A 591M, Commercial Steel (CS), Class B coating; mill phosphatized; suitable for unexposed applications; stretcher-leveled standard of flatness where used for face sheets.
2.3 DOORS
A. General: Provide doors of sizes, thicknesses, and designs indicated.
B. Interior Doors: Provide doors complying with requirements indicated below by referencing ANSI 250.8 for level and model and ANSI A250.4 for physical-endurance level:
1. Level 2 and Physical Performance Level A (Heavy Duty), Model 2 (Seamless) (18 gauge face).
C. Exterior Doors: Provide doors complying with requirements indicated below by referencing ANSI A250.8 for level and model and ANSI A250.4 for physical-endurance level:
1. Level 4 and Physical Performance Level A (Maximum Duty), Model 2 (Seamless) (14 gauge face).
D. Vision Lite Systems: Manufacturer's standard kits consisting of glass lite moldings to accommodate glass thickness and size of vision lite indicated.
BC&A STEEL DOORS AND FRAMES JVWCD PAGE 08110-3 CENTRAL PIPELINE PROJECT 2.4 FRAMES
A. General: Provide steel frames for doors, transoms, sidelights, borrowed lights, and other openings that comply with ANSI A250.8 and with details indicated for type and profile. Conceal fastenings, unless otherwise indicated.
B. Exterior Frames: Fabricated from metallic-coated steel sheet.
1. Fabricate frames with mitered or coped and welded face corners and seamless face joints. 2. Frames for Level 4 Steel Doors: 0.067-inch- (1.7-mm-) (16 gauge) thick steel sheet.
C. Interior Frames: Fabricated from cold-rolled steel sheet, unless otherwise indicated to comply with exterior frame requirements.
1. Fabricate frames with mitered or coped and welded face corners and seamless face joints. 2. Frames for Level 2 Steel Doors: 0.067-inch- (16 gauge) thick steel sheet. 3. Frames for Wood Doors: 0.067-inch- (16 gauge) thick steel sheet. 4. Frames for Borrowed Lights: 0.067-inch- (16 gauge) thick steel sheet.
D. Door Silencers: Except on weather-stripped frames, fabricate stops to receive three silencers on strike jambs of single-door frames and two silencers on heads of double-door frames.
E. Plaster Guards: Provide 0.016-inch-thick, steel sheet plaster guards or mortar boxes to close off interior of openings; place at back of hardware cutouts where mortar or other materials might obstruct hardware operation.
F. Supports and Anchors: Fabricated from not less than 0.042-inch-thick, electrolytic zinc-coated or metallic-coated steel sheet.
1. Wall Anchors in Masonry Construction: 0.177-inch-diameter, steel wire complying with ASTM A 510 may be used in place of steel sheet.
G. Inserts, Bolts, and Fasteners: Manufacturer's standard units. Where zinc-coated items are to be built into exterior walls, comply with ASTM A 153/A 153M, Class C or D as applicable.
2.5 FABRICATION
A. General: Fabricate steel door and frame units to comply with ANSI A250.8 and to be rigid, neat in appearance, and free from defects including warp and buckle. Where practical, fit and assemble units in manufacturer's plant. Clearly identify Work that cannot be permanently factory assembled before shipment, to assure proper assembly at Project site.
B. Exterior Door Construction: For exterior locations and elsewhere as indicated, fabricate doors, panels, and frames from metallic-coated steel sheet. Close top and bottom edges of doors flush as an integral part of door construction or by addition of 0.053-inch- thick, metallic-coated steel channels with channel webs placed even with top and bottom edges.
BC&A STEEL DOORS AND FRAMES JVWCD PAGE 08110-4 CENTRAL PIPELINE PROJECT C. Interior Door and Panel Faces: Fabricate exposed faces of doors and panels, including stiles and rails of nonflush units, from the following material:
1. Cold-rolled steel sheet. 2. Metallic-coated steel sheet at all wet areas.
D. Core Construction: Manufacturer's standard core construction that produces a door complying with SDI standards.
E. Clearances for Non-Fire-Rated Doors: Not more than 1/8 inch at jambs and heads, except not more than 1/4 inch between pairs of doors. Not more than 3/4 inch at bottom.
F. Clearances for Fire-Rated Doors: As required by NFPA 80.
G. Single-Acting, Door-Edge Profile: Beveled edge.
H. Tolerances: Comply with SDI 117, "Manufacturing Tolerances for Standard Steel Doors and Frames."
I. Fabricate concealed stiffeners, reinforcement, edge channels, louvers, and moldings from either cold- or hot-rolled steel sheet.
J. Exposed Fasteners: Unless otherwise indicated, provide countersunk flat or oval heads for exposed screws and bolts.
K. Thermal-Rated (Insulating) Assemblies: At exterior locations and elsewhere as shown or scheduled, provide doors fabricated as thermal-insulating door and frame assemblies and tested according to ASTM C 236 or ASTM C 976 on fully operable door assemblies.
1. Unless otherwise indicated, provide thermal-rated assemblies with U-value of 0.41 Btu/sq. ft. x h x deg F or better.
L. Hardware Preparation: Prepare doors and frames to receive mortised and concealed hardware according to final door hardware schedule and templates provided by hardware supplier. Comply with applicable requirements in ANSI A250.6 and ANSI A115 Series specifications for door and frame preparation for hardware.
1. For concealed overhead door closers, provide space, cutouts, reinforcement, and provisions for fastening in top rail of doors or head of frames, as applicable.
M. Frame Construction: Fabricate frames to shape shown.
1. Fabricate frames with mitered or coped and continuously welded corners and seamless face joints. 2. For exterior applications, fabricate frames with mitered or coped and continuously welded corners and seamless face joints. 3. Provide welded frames with temporary spreader bars. 4. Provide terminated stops where indicated. 5. Provide metallic-coated steel sheet at all exterior locations and at all wet areas.
BC&A STEEL DOORS AND FRAMES JVWCD PAGE 08110-5 CENTRAL PIPELINE PROJECT N. Reinforce doors and frames to receive surface-applied hardware. Drilling and tapping for surface-applied hardware may be done at Project site.
1. Provide auxiliary hinge reinforcement at all hinge locations on every frame.
O. Locate hardware as indicated on Shop Drawings or, if not indicated, according to ANSI A250.8.
P. Glazing Stops: Manufacturer's standard, formed from 0.032-inch-thick steel sheet.
1. Provide nonremovable stops on outside of exterior doors and on secure side of interior doors for glass, louvers, and other panels in doors. 2. Provide screw-applied, removable, glazing stops on inside of glass, louvers, and other panels in doors.
Q. Astragals: As required by NFPA 80 to provide fire ratings indicated.
2.6 FINISHES
A. Prime Finish: Manufacturer's standard, factory-applied coat of rust-inhibiting primer complying with ANSI A250.10 for acceptance criteria.
PART 3 – EXECUTION
3.1 INSTALLATION
A. General: Install steel doors, frames, and accessories according to Shop Drawings, manufacturer's data, and as specified.
B. Placing Frames: Comply with provisions in SDI 105, unless otherwise indicated. Set frames accurately in position, plumbed, aligned, and braced securely until permanent anchors are set. After wall construction is completed, remove temporary braces and spreaders, leaving surfaces smooth and undamaged.
1. Except for frames located in existing walls or partitions, place frames before construction of enclosing walls and ceilings. 2. In masonry construction, provide at least three wall anchors per jamb; install adjacent to hinge location on hinge jamb and at corresponding heights on strike jamb. Acceptable anchors include masonry wire anchors and masonry T-shaped anchors. 3. In existing concrete or masonry construction, provide at least three completed opening anchors per jamb; install adjacent to hinge location on hinge jamb and at corresponding heights on strike jamb. Set frames and secure to adjacent construction with bolts and masonry anchorage devices. 4. In metal-stud partitions, provide at least three wall anchors per jamb; install adjacent to hinge location on hinge jamb and at corresponding heights on strike jamb. Attach wall anchors to studs with screws. 5. Install fire-rated frames according to NFPA 80. 6. For openings 90 inches or more in height, install an additional anchor at hinge and strike jambs.
BC&A STEEL DOORS AND FRAMES JVWCD PAGE 08110-6 CENTRAL PIPELINE PROJECT C. Door Installation: Comply with ANSI A250.8. Fit hollow-metal doors accurately in frames, within clearances specified in ANSI A250.8. Shim as necessary to comply with SDI 122 and ANSI/DHI A115.1G.
1. Fire-Rated Doors: Install within clearances specified in NFPA 80. 2. Smoke-Control Doors: Install to comply with NFPA 105.
3.2 ADJUSTING AND CLEANING
A. Prime-Coat Touchup: Immediately after installation, sand smooth any rusted or damaged areas of prime coat and apply touch up of compatible air-drying primer.
END OF SECTION
BC&A STEEL DOORS AND FRAMES JVWCD PAGE 08110-7 CENTRAL PIPELINE PROJECT
SECTION 08220 FIBERGLASS-REINFORCED PLASTIC DOORS AND FRAMES
Specifications Referenced from this Section include: 01090 – Reference Standards 01300 – Submittals
PART 1 – GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall furnish and install all fiberglass-reinforced plastic (FRP) doors, frames, and related items, complete and operable, including all finish hardware and all appurtenant work, all in accordance with the requirements of the Contract Documents.
1.2 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS
A. Codes: All codes, as referenced herein, are specified in Section 01090 - Reference Standards.
B. Commercial Standards:
ASTM A 236 Test Method for Steady-State Thermal Performance of Building Assemblies by Means of a Guarded Hot Box
ASTM E 413, ASTM E 90 Classification for Determination of Sound Transmission Class
ANSI A 151.1 Test Method for Swing Test and Twist Test after More than 1 Million Cycles
NFPA 80 Fire Doors and Windows
NFPA 252 Fire Tests of Door and Assemblies
ASTM E 152 Methods of Fire Test of Door Assemblies
UL 10B Underwriters’ Laboratories, Inc. Fire Tests of Door Assemblies
C. Manufacturers' Standards: In addition to the standards listed above, the FRP doors and frames and their installation shall be in accordance with the manufacturer's published recommendations and specifications.
1.3 CONTRACTOR SUBMITTALS
A. General: Submittals shall be in accordance with Section 01300 - Contractor Submittals.
B. Shop Drawings: Shop drawings shall show details of the products and systems and connections to adjoining materials. Schedules showing sizes, types, and locations of door louvers and glass shall be submitted along with manufacturer's installation instructions.
BC&A FIBERGLASS REINFORCED PLASTIC DOOR AND FRAMES JVWCD PAGE 08220-1 CENTRAL PIPELINE PROJECT C. Manufacturer's Literature: The Contractor shall submit manufacturer’s specifications, installation instructions and general recommendations. Data substantiating that products to be furnished comply with the requirements of the Contract Documents shall be submitted.
1.4 PRODUCT DELIVERY, STORAGE, AND HANDLING
A. Doors and frames shall be shipped and stored with temporary stiffeners and spacers in place to prevent distortion.
B. Doors and frames shall be delivered in original, unbroken packages, containers, or bundles bearing the name of the manufacturer.
C. Doors and frames shall be carefully stored on wood blocking in an area that is protected from the elements. Storage shall be in a manner that will prevent damage or marring of finish.
PART 2 – PRODUCTS
2.1 MATERIALS AND FABRICATION – GENERAL
A. Manufacturers, or approved equal:
Corrim Company Fib-R-Dor by Advance Fiberglass, Inc. Chem-Pruf Door Co.
2.2 DOOR CONSTRUCTION
A. FRP door panels shall be made of fiberglass reinforced plastics using resins and reinforcements tailored to the corrosive environment of this particular project. Door panel shall have a fiberglass content of not less than 40% by weight and all exterior surfaces shall be treated with ultraviolet inhibitors. The door panels will be flush construction having no seams or cracks. The manufacturer shall provide all mortises. Mortises shall be reinforced with a polyester-based resin filled with 1/4” chopped glass strands and aerosil. Steel, wood or other reinforcement material other than a polyester-based resin filled with 1/4” chopped glass strands and aerosil will not be accepted. Unless otherwise specified, door thickness shall be nominal 1-3/4-inch thick, with a 15 mils (3 mils) color gel-coat factory-finish. Standard door face sheets shall be a maximum of .125” in thickness.
B. FRP Face Sheet: One continuous piece of FRP material of suitable structure integrity and resin composition to provide a door panel with the ability to perform reliably in the specified environment and physical constraints.
1. Standard face sheets shall be manufactured using a corrosion resistant isophthalic polyester resin system with light stabilizing additives. The resin shall be reinforced with not less than 40% fiberglass by weight. 2. Face sheet shall be not greater than 0.125” in thickness. 3. Finish: Gel coat, not less than 15 mil (3 mils) thickness. The color shall be as selected by the Engineer from manufacturer’s color selection charts.
BC&A FIBERGLASS REINFORCED PLASTIC DOOR AND FRAMES JVWCD PAGE 08220-2 CENTRAL PIPELINE PROJECT C. Door Core: All voids between the door faces shall be completely filled with an approved material as dictated by the environment or installation and in compliance with required STC rating.
1. Urethane core - 1-1/2” thick rigid block of urethane shall be laminated to the interior of the face sheets. The “K” factor shall be .14 BTU in./hr./sq. ft. 2-4 lb. Density, minimum.
D. Door Stiles and Rails: Door panels shall be constructed with the use of a full stile and rail structure. Doors that do not have an engineered stile and rail system fabricated entirely from pultruded FRP components are not acceptable and will not be accepted. The pultruded FRP stile and rail system shall, of themselves, provide the structural integrity for the door panel. The stile and rail system, of itself, will provide an impenetrable barrier between the edge of the door and the core material. The stiles and rails shall provide the primary support for hardware accessories and attachments. Stiles and rails shall be 1- 1/2” square pultruded fiberglass tubes. A polyester-based resin filled with 1/4” chopped glass strands and aerosil will be used for all reinforcements, corner blocks and structural support. The top and bottom rails shall allow 1-1/4” of height alterability without loss of the panel’s integrity or warranty.
E. Reinforcements: Door panels will be adequately reinforced and compression members fabricated from suitable corrosion resistant materials (Pultruded FRP tubes filled with a polyester based resin fill with 1/4” chopped glass strands) so as to accommodate hinges, (both mortise and surface) closer units, locksets - (both cylindrical and mortise type), kickplates, etc. The screw withdrawal strength, for #12 x 1-1/4” long wood screws will be in excess of 900 pounds. Steel, wood or other reinforcement material other than specified above will not be accepted or approved.
F. Thru-bolting: Doors shall contain sufficient internal reinforcing in the areas of thru-bolt hardware as specified. Reinforcement will be the same corrosion-resistant compression material as stated above (Pultruded FRP Tubes filled with a polyester based resin fill with 1/4” chopped glass strands) which possess the ability to resist typical thru-bolt torqing and maintain the sealed integrity of the panel.
G. Hardware Preparations: All doors will be mortised and reinforced to allow field application of hinges, locks, pulls, bolts, etc., in accordance with details, approved hardware schedule and templates supplied by the hardware supplier.
H. Door Hardware:
1. Hardware hinges shall be stainless steel 4-1/2” x 4-1/2” full mortise, ball bearings applied with stainless steel fasteners. 2. Closer shall be Norton 1604 stainless steel, or approved equal. 3. Kickplate shall be 18-gauge stainless steel with a brushed finish unless otherwise specified. Edges shall be beveled. 4. Standard passage and standard lockset ball type, grade 2 shall be stainless steel on exposed surfaces.
2.3 FABRICATION
A. FRP astragals for double doors shaped specifically for double doors shall be provided.
BC&A FIBERGLASS REINFORCED PLASTIC DOOR AND FRAMES JVWCD PAGE 08220-3 CENTRAL PIPELINE PROJECT 2.4 FINISH
A. Gel Coat: Unless otherwise specified, finish shall consist of 15 mils ( 3 mils) color gel coat. Only gel coat finishes are acceptable on the door panels unless otherwise approved or requested in writing.
B. Color: The color shall be as selected by the Engineer from the manufacturer’s color selection charts.
2.5 DOOR FRAMES
A. Frames will be constructed from pultruded fiberglass component parts and materials in accordance with the manufacturer’s standard method of construction and the project details.
B. Frames will be reinforced with anchor blocks and prepared for the attachments of hinges, closer units, panic exit devices and any other pertinent hardware. When required, the factory shall prepare mortises for hinges unless specific requirements for field installation are noted. All hardware reinforcements will be made from polymer materials. No steel or wood inserts or reinforcements will be accepted or allowed. Alternate materials may be used other than steel or wood, upon pre-approval.
2.6 FRAME ACCESSORIES
A. Anchors: Frame anchors shall be dictated by the prevailing conditions of the installation and frame units will be suitably prepared to meet the requirements of the installation.
B. Frames that are fabricated from component parts, i.e., the stop unit is separate structure which will be attached after the installation of the frame has occurred, shall require that a stop cap be provided to cover any exposed screw heads, etc.
C. Frames that require masonry anchors and tabs shall be suitably prepared to ensure sound and reliable installation.
2.7 FRAME FABRICATION
A. Frames fabricated for Knock Down (KD) field assembly shall provide neatly butted or mitered corner connection.
B. Silencers: Provide silencers for single doors and on frame head at double doors without mullions.
2.8 FINISH
A. Gel Coat: Unless otherwise specified, finish will consist of 15 mils (3 mils) color gel coat. Only gel coat finishes are acceptable on the frames unless otherwise approved or requested in writing.
BC&A FIBERGLASS REINFORCED PLASTIC DOOR AND FRAMES JVWCD PAGE 08220-4 CENTRAL PIPELINE PROJECT 2.9 TRANSOM PANELS AND FRAMES
A. Transom panels and frames shall be identical to those used for the associated door. Transom and door head shall be easily removable.
PART 3 – EXECUTION
3.1 EXAMINATION
A. Inspect substrates and conditions under which the work of this section will be performed, and verify that installation properly may commence. Do not proceed with the work until unsatisfactory conditions have been resolved fully.
3.2 INSTALLATION
A. General: Comply with manufacturer’s instructions, except where more stringent requirements are shown or specified and except where project conditions require extra precautions or provisions to ensure satisfactory performance of the work.
B. Frame Installation: Install frames in accordance with ANSI/SDI-100 and manufacturers written instructions.
C. Door Installation: Install doors in accordance with ANSI/SDI-100 and as specified in NFPA Standard N.80.
D. Tolerances: Install products of this section to within tolerances that conform to Steel Door Institute’s (SDI) requirements and manufacturer’s standard.
3.3 ADJUSTING
A. Final Adjustments: Upon achieving substantial completion of work, adjust all operable components to ensure they are properly installed and functioning smoothly. Replace any component that cannot be adjusted for proper operation.
3.4 CLEANING
A. During progress of the work, remove from project site all discarded material, rubbish and debris resulting from the work.
B. Upon completion, clean all surfaces which have become soiled or coated as a result of work of this section, using proper methods which will not scratch or otherwise damage finished surfaces.
C. For cleaning, use only products and techniques acceptable to the manufacturer of products being cleaned.
BC&A FIBERGLASS REINFORCED PLASTIC DOOR AND FRAMES JVWCD PAGE 08220-5 CENTRAL PIPELINE PROJECT 3.5 PROTECTION
A. General: Institute protective procedures and install protective materials as required to ensure that work of this section will be without damage or deterioration at substantial completion.
END OF SECTION
BC&A FIBERGLASS REINFORCED PLASTIC DOOR AND FRAMES JVWCD PAGE 08220-6 CENTRAL PIPELINE PROJECT SECTION 08311 ACCESS DOORS AND FRAMES
PART 1 – GENERAL
1.1 RELATED DOCUMENTS
A. Drawing and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section includes the following:
1. Wall access doors and frames. 2. Fire-rated wall access doors and frames. 3. Ceiling access doors and frames. 4. Fire-rated ceiling access doors and frames.
B. Related Sections include the following:
1. Division 1 Section "LEED Requirements" for LEED certification targets, related LEED requirements, recycled content minima, other LEED criteria and constraints. 2. Information attached for reference, including LEED Checklist for Project building(s), indicating which LEED credits are targeted for attainment. 3. LEED reference documents, not attached but available for use, including the “LEED- New Construction v.2.2 Rating System,” explaining requirements for each prerequisite and credit, and the “LEED-New Construction v2.2 Reference Guide,” detailing requirements and documentation options for application for each prerequisite and credit. 4. Division 3 Section "Cast-in-Place Concrete" for blocking out openings for access doors and frames in concrete. 5. Division 4 Section "Unit Masonry Assemblies" for anchoring and grouting access door frames set in masonry construction. 6. Division 7 Section "Roof Accessories" for roof hatches. 7. Division 8 Section "Door Hardware" for mortise or rim cylinder locks and master keying. 8. Division 15 Section "Duct Accessories" for heating and air-conditioning duct access doors. 9. Division 15 Section "Storm Drainage Piping" for connection of floor door drainage couplings to drains.
1.3 SUBMITTALS
A. Product Data: For each type of door and frame indicated. Include construction details relative to materials, individual components and profiles, finishes, and fire ratings (if required) for access doors and frames.
BC&A ACCESS DOORS AND FRAMES JVWCD PAGE 08311-1 CENTRAL PIPELINE PROJECT
B. LEED Submittals:
1. Product Data for Credit MR 4.1 and Credit MR 4.2: Indicating percentages by weight of postconsumer and preconsumer recycled content for products having recycled content. a. Include statement indicating costs for each product having recycled content.
C. Shop Drawings: Show fabrication and installation details of customized doors and frames. Include plans, elevations, sections, details, and attachments to other Work.
D. Schedule: Provide complete door and frame schedule, including types, general locations, sizes, construction details, latching or locking provisions, and other data pertinent to installation.
E. Coordination Drawings: Reflected ceiling plans drawn to scale and coordinating penetrations and ceiling-mounted items with concealed framing, suspension systems, piping, ductwork, and other construction. Show the following:
1. Method of attaching door frames to surrounding construction. 2. Ceiling-mounted items including access doors and frames, lighting fixtures, diffusers, grilles, speakers, sprinklers, and special trim.
1.4 QUALITY ASSURANCE
A. Source Limitations: Obtain doors and frames through one source from a single manufacturer.
B. Fire-Rated Access Doors and Frames: Units complying with NFPA 80 that are identical to access door and frame assemblies tested for fire-test-response characteristics per the following test method and that are labeled and listed by UL, ITS, or another testing and inspecting agency acceptable to authorities having jurisdiction:
1. NFPA 252 or UL 10B for vertical access doors. 2. ASTM E 119 or UBC Standard 7.1 for horizontal access doors and frames.
C. Size Variations: Obtain Architect's acceptance of manufacturer's standard-size units, which may vary slightly from sizes indicated.
1.5 COORDINATION
A. Verification: Determine specific locations and sizes for access doors needed to gain access to concealed equipment, and indicate on schedule specified in "Submittals" Article.
BC&A ACCESS DOORS AND FRAMES JVWCD PAGE 08311-2 CENTRAL PIPELINE PROJECT
PART 2 – PRODUCTS
2.1 MANUFACTURERS
A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:
1. Access Doors: a. J. L. Industries, Inc. b. Larsen's Manufacturing Company. c. Milcor Limited Partnership.
2.2 MATERIALS
A. Steel Plates, Shapes, and Bars: ASTM A 36/A 36M.
B. Electrolytic Zinc-Coated Steel Sheet: ASTM A 591/A 591M, Commercial Steel (CS), with Class C coating and phosphate treatment to prepare surface for painting; with minimum thickness indicated representing specified nominal thickness according to ASTM A 568/A 568M for uncoated base metal.
1. Recycled Content: Provide steel sheet with average recycled content such that postconsumer recycled content plus one-half of preconsumer recycled content is not less than 25 percent.
C. Drywall Beads: Edge trim formed from 0.0299-inch (0.76-mm) zinc-coated steel sheet formed to receive joint compound and in size to suit thickness of gypsum board.
2.3 PAINT
A. Shop Primer for Ferrous Metal: Fast-curing, lead- and chromate-free, universal modified-alkyd primer complying with performance requirements in FS TT-P-664; selected for good resistance to normal atmospheric corrosion, compatibility with finish paint systems indicated, and capability to provide a sound foundation for field-applied topcoats despite prolonged exposure.
2.4 ACCESS DOORS AND FRAMES
A. Flush, Insulated, Fire-Rated Access Doors and Trimless Frames: Fabricated from steel sheet.
1. Locations: Gypsum board wall and ceiling surfaces. 2. Fire-Resistance Rating: One hour and as scheduled. 3. Temperature Rise Rating: 250 deg F (139 deg) C at the end of 30 minutes. 4. Door: Flush panel with a core of mineral-fiber insulation enclosed in sheet metal with a minimum thickness of 0.036 inch (0.9 mm). 5. Frame: Minimum 0.060-inch- (1.5-mm-) thick sheet metal with drywall bead. 6. Hinges: Continuous piano hinge. 7. Automatic Closer: Spring type.
BC&A ACCESS DOORS AND FRAMES JVWCD PAGE 08311-3 CENTRAL PIPELINE PROJECT
8. Latch: Self-latching bolt operated by knurled knob with interior release. 9. Lock: Key-operated cylinder lock with interior release.
B. Flush Access Doors and Frames with Exposed Trim: Fabricated from steel sheet.
1. Locations: Masonry, concrete and ceramic-tile wall surfaces. 2. Door: Minimum 0.060-inch- (1.5-mm-) thick sheet metal, set flush with exposed face flange of frame. 3. Frame: Minimum 0.060-inch- (1.5-mm-) thick sheet metal with 1-inch-(25-mm-) wide, surface-mounted trim. 4. Hinges: Continuous piano hinge. 5. Latch: Screwdriver-operated cam latch. 6. Lock: Key-operated cylinder lock.
C. Flush Access Doors and Trimless Frames: Fabricated from steel sheet.
1. Locations: Gypsum board wall and ceiling surfaces. 2. Door: Minimum 0.060-inch- (1.5-mm-) thick sheet metal, set flush with surrounding finish surfaces. 3. Frame: Minimum 0.060-inch- (1.5-mm-) thick sheet metal with drywall bead. 4. Hinges: Continuous piano hinge. 5. Latch: Screwdriver-operated cam latch. 6. Lock: Key-operated cylinder lock.
2.5 FABRICATION
A. General: Provide access door assemblies manufactured as integral units ready for installation.
B. Metal Surfaces: For metal surfaces exposed to view in the completed Work, provide materials with smooth, flat surfaces without blemishes. Do not use materials with exposed pitting, seam marks, roller marks, rolled trade names, or roughness.
C. Steel Doors and Frames: Grind exposed welds smooth and flush with adjacent surfaces. Furnish attachment devices and fasteners of type required to secure access panels to types of supports indicated.
1. Exposed Flanges: Nominal 1 to 1-1/2 inches (25 to 38 mm) wide around perimeter of frame. 2. For trimless frames with drywall bead for installation in gypsum board assembly, provide edge trim for gypsum board securely attached to perimeter of frames. 3. Provide mounting holes in frames to attach frames to framing in drywall construction and to attach masonry anchors in masonry construction. Furnish adjustable metal masonry anchors.
D. Latching Mechanisms: Furnish number required to hold doors in flush, smooth plane when closed.
1. For cylinder lock, furnish two keys per lock and key all locks alike.
BC&A ACCESS DOORS AND FRAMES JVWCD PAGE 08311-4 CENTRAL PIPELINE PROJECT
2.6 FINISHES, GENERAL
A. Comply with NAAMM's "Metal Finishes Manual for Architectural and Metal Products" for recommendations for applying and designating finishes.
B. Finish metal fabrications after assembly.
2.7 METALLIC-COATED STEEL FINISHES
A. Galvanizing of Steel Shapes and Plates: Hot-dip galvanize items indicated to comply with applicable standard listed below:
1. ASTM A 153/A 153M, for galvanizing steel and iron hardware.
B. Surface Preparation: Clean surfaces with nonpetroleum solvent so surfaces are free of oil and other contaminants. For galvanized surfaces, apply, after cleaning, a conversion coating suited to the organic coating to be applied over it. For metallic-coated surfaces, clean welds, mechanical connections, and abraded areas, and apply galvanizing repair paint specified below to comply with ASTM A 780.
1. Galvanizing Repair Paint: High-zinc-dust-content paint for regalvanizing welds in steel, complying with SSPC-Paint 20.
C. Factory Priming for Field-Painted Finish: Apply shop primer immediately after cleaning and pretreating.
2.8 STEEL FINISHES
A. Surface Preparation: Prepare uncoated ferrous-metal surfaces to comply with minimum requirements indicated below for SSPC surface-preparation specifications and environmental exposure conditions of installed metal fabrications:
1. Exteriors (SSPC Zone 1B): SSPC-SP 6/NACE No. 3, "Commercial Blast Cleaning." 2. Interiors (SSPC Zone 1A): SSPC-SP 3, "Power Tool Cleaning."
B. Apply shop primer to uncoated surfaces of metal fabrications. Comply with SSPC-PA 1, "Paint Application Specification No. 1," for shop painting.
PART 3 – EXECUTION
3.1 PREPARATION
A. Advise installers of other work about specific requirements relating to access door and floor door installation, including sizes of openings to receive access door and frame, as well as locations of supports, inserts, and anchoring devices.
3.2 INSTALLATION
A. Comply with manufacturer's written instructions for installing access doors and frames and floor doors and frames.
BC&A ACCESS DOORS AND FRAMES JVWCD PAGE 08311-5 CENTRAL PIPELINE PROJECT
B. Set frames accurately in position and attach securely to supports with plane of face panels aligned with adjacent finish surfaces.
C. Install access doors with trimless frames and floor doors flush with adjacent finish surfaces or recessed to receive finish material.
3.3 ADJUSTING AND CLEANING
A. Adjust doors and hardware after installation for proper operation.
B. Remove and replace doors and frames that are warped, bowed, or otherwise damaged.
END OF SECTION
BC&A ACCESS DOORS AND FRAMES JVWCD PAGE 08311-6 CENTRAL PIPELINE PROJECT
SECTION 08331 OVERHEAD COILING DOORS
PART 1 – GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section includes the following types of manually and electric-motor-operated overhead coiling doors:
1. Insulated service doors.
B. Related Sections include the following:
1. Division 5 Section "Metal Fabrications" for miscellaneous steel supports. 2. Division 8 Section "Door Hardware" for lock cylinders and keying. 3. Division 9 Section "Painting" for field-applied paint finish. 4. Division 16 Sections for electrical service and connections for powered operators and accessories.
1.3 DEFINITIONS
A. Operation Cycle: One cycle of a door is complete when it is moved from the closed position to the fully open position and returned to the closed position.
1.4 PERFORMANCE REQUIREMENTS
A. Structural Performance: Provide overhead coiling doors capable of withstanding the effects of gravity loads and the following loads and stresses without evidencing permanent deformation of door components:
1. Wind Load: Uniform pressure (velocity pressure) of 20 lbf/sq. ft. (960 Pa), acting inward and outward.
B. Operation-Cycle Requirements: Provide overhead coiling door components and operators capable of operating for not less than 20,000 cycles and for 10 cycles per day.
1.5 SUBMITTALS
A. Submittals shall be provided with the information required within this specification and conform to the requirements of 01300 – Contractor Submittals.
BC&A OVERHEAD COILING DOORS JVWCD PAGE 08331-1 CENTRAL PIPELINE PROJECT B. Product Data: For each type and size of overhead coiling door and accessory. Include the following:
1. Summary of forces and loads on walls and jambs.
C. Shop Drawings: For special components and installations not dimensioned or detailed in manufacturer's product data.
D. Samples for Selection: Manufacturer's color charts showing full range of colors available for units with factory-applied finishes.
E. Qualification Data: For Installer.
1.6 QUALITY ASSURANCE
A. Installer Qualifications: Manufacturer's authorized representative who is trained and approved for both installation and maintenance of units required for this Project.
B. Source Limitations: Obtain overhead coiling doors through one source from a single manufacturer.
1. Obtain operators and controls from overhead coiling door manufacturer. 2. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100.
PART 2 – PRODUCTS
2.1 MANUFACTURERS
A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:
1. Atlas Door; Div. of Clopay Building Products Company, Inc. 2. Vortex Industries, Inc. 3. Cookson Company. 4. Cornell Iron Works Inc. 5. Overhead Door Corp. 6. Pacific Rolling Doors Co. 7. Raynor. 8. Wayne-Dalton Corp.
2.2 DOOR CURTAIN MATERIALS AND CONSTRUCTION
A. Door Curtains: Fabricate overhead coiling door curtain of interlocking slats, designed to withstand wind loading indicated, in a continuous length for width of door without splices. Unless otherwise indicated, provide slats of thickness and mechanical properties
BC&A OVERHEAD COILING DOORS JVWCD PAGE 08331-2 CENTRAL PIPELINE PROJECT recommended by door manufacturer for performance, size, and type of door indicated, and as follows:
1. Steel Door Curtain Slats: Zinc-coated (galvanized), cold-rolled structural steel (SS) sheet; complying with ASTM A 653/A 653M, G90 (Z275) coating designation. a. Minimum Base-Metal (Uncoated) Thickness: 0.0209 inch (0.55 mm). b. Flat profile slats. 2. Insulation: Fill slat with manufacturer's standard rigid cellular polystyrene or polyurethane-foam-type thermal insulation complying with maximum flame-spread and smoke-developed indexes of 75 and 450, respectively, according to ASTM E 84. Enclose insulation completely within metal slat faces. 3. Inside Curtain Slat Face: To match material of outside metal curtain slat.
B. Endlocks and Windlocks for Service Doors: Malleable-iron casings galvanized after fabrication, secured to curtain slats with galvanized rivets or high-strength nylon. Provide locks on not less than alternate curtain slats for curtain alignment and resistance against lateral movement.
C. Bottom Bar for Service Doors: Consisting of 2 angles, each not less than 1-1/2 by 1-1/2 by 1/8 inch (38 by 38 by 3 mm) thick; galvanized, stainless-steel, or aluminum extrusions to suit type of curtain slats.
1. Astragal: Provide a replaceable, adjustable, continuous, compressible gasket of flexible vinyl, rubber, or neoprene; for placement between angles or fitted to shape, as a cushion bumper for interior door.
D. Curtain Jamb Guides for Service Doors: Fabricate curtain jamb guides of steel angles or channels and angles, with sufficient depth and strength to retain curtain, to allow curtain to operate smoothly, and to withstand loading. Build up units with not less than 3/16-inch- (5-mm-) thick galvanized steel sections complying with ASTM A 36/A 36M and ASTM A 123/A 123M. Slot bolt holes for guide adjustment. Provide removable stops on guides to prevent overtravel of curtain, and a continuous bar for holding windlocks.
2.3 HOODS AND ACCESSORIES
A. Hood: Form to act as weatherseal and entirely enclose coiled curtain and operating mechanism at opening head. Contour to fit end brackets to which hood is attached. Roll and reinforce top and bottom edges for stiffness. Provide closed ends for surface-mounted hoods and provide fascia for any portion of between-jamb mounting projecting beyond wall face. Provide intermediate support brackets as required to prevent sagging.
1. Fabricate hoods for steel doors of minimum 0.028-inch- (0.7-mm-) thick, hot-dip galvanized steel sheet with G90 (Z275) zinc coating, complying with ASTM A 653/A 653M. 2. Shape: Round.
BC&A OVERHEAD COILING DOORS JVWCD PAGE 08331-3 CENTRAL PIPELINE PROJECT B. Weatherseals: Provide replaceable, adjustable, continuous, compressible weather-stripping gaskets fitted to bottom and top of exterior doors, unless otherwise indicated. At door head, use 1/8-inch- (3-mm-) thick, replaceable, continuous sheet secured to inside of hood.
1. In addition, provide replaceable, adjustable, continuous, flexible, 1/8-inch- (3-mm-) thick seals of flexible vinyl, rubber, or neoprene at door jambs for a weathertight installation.
C. Bird Screen: Overhead doors must be installed with a bird deterrent system to prevent birdlife from entering the overhead coil and housing assembly from the building exterior. The system shall be manufacturer current model. All hardware potentially exposed to rain shall be stainless steel. All other components shall be coated and protected to comply with the requirements of 09900 – Coatings and Painting.
D. Push/Pull Handles: For push-up-operated or emergency-operated doors, provide galvanized steel lifting handles on each side of door.
E. Slide Bolt: Fabricate with side-locking bolts to engage through slots in tracks for locking by padlock, located on both left and right jamb sides, operable from coil side.
F. Chain Lock Keeper: Suitable for padlock.
G. If door unit is power operated, provide safety interlock switch to disengage power supply when door is locked.
2.4 COUNTERBALANCING MECHANISM
A. General: Counterbalance doors by means of adjustable-tension, steel helical torsion spring mounted around a steel shaft and contained in a spring barrel connected to door curtain with barrel rings. Use grease-sealed bearings or self-lubricating graphite bearings for rotating members.
B. Counterbalance Barrel: Fabricate spring barrel of hot-formed, structural-quality, welded or seamless carbon-steel pipe, of sufficient diameter and wall thickness to support rolled-up curtain without distortion of slats and to limit barrel deflection to not more than 0.03 in./ft. (2.5 mm/m) of span under full load.
C. Provide spring balance of one or more oil-tempered, heat-treated steel helical torsion springs. Size springs to counterbalance weight of curtain, with uniform adjustment accessible from outside barrel. Provide cast-steel barrel plugs to secure ends of springs to barrel and shaft.
D. Fabricate torsion rod for counterbalance shaft of cold-rolled steel, sized to hold fixed spring ends and carry torsional load.
E. Brackets: Provide mounting brackets of manufacturer's standard design, either cast iron or cold-rolled steel plate.
BC&A OVERHEAD COILING DOORS JVWCD PAGE 08331-4 CENTRAL PIPELINE PROJECT 2.5 MANUAL DOOR OPERATORS
A. Chain-Hoist Operator: Provide manual chain-hoist operator consisting of endless steel hand chain, chain pocket wheel and guard, and gear-reduction unit with a maximum 35-lbf (155-N) force for door operation. Provide alloy steel hand chain with chain holder secured to operator guide.
2.6 ELECTRIC DOOR OPERATORS
A. General: Provide electric door operator assembly of size and capacity recommended and provided by door manufacturer for door and operation-cycle requirements specified, with electric motor and factory-prewired motor controls, starter, gear-reduction unit, solenoid-operated brake, clutch, remote-control stations, control devices, integral gearing for locking door, and accessories required for proper operation.
B. Comply with NFPA 70.
C. Disconnect Device: Provide hand-operated disconnect or mechanism for automatically engaging chain and sprocket operator and releasing brake for emergency manual operation while disconnecting motor without affecting timing of limit switch. Mount disconnect and operator so they are accessible from floor level. Include interlock device to automatically prevent motor from operating when emergency operator is engaged.
D. Design operator so motor may be removed without disturbing limit-switch adjustment and without affecting emergency auxiliary operator.
E. Provide control equipment complying with NEMA ICS 1, NEMA ICS 2, and NEMA ICS 6, with NFPA 70 Class 2 control circuit, maximum 24-V, ac or dc.
F. Door-Operator Type: Provide wall-, hood-, or bracket-mounted, jackshaft-type door operator unit consisting of electric motor, worm-gear running-in-oil drive, and chain and sprocket secondary drive.
G. Electric Motors: Provide high-starting torque, reversible, continuous-duty, Class A insulated, electric motors complying with NEMA MG 1; with overload protection; sized to start, accelerate, and operate door in either direction from any position, at not less than 2/3 fps (0.2 m/s) and not more than 1 fps (0.3 m/s), without exceeding nameplate ratings or service factor.
1. Type: Polyphase, medium-induction type. 2. Service Factor: According to NEMA MG 1, unless otherwise indicated. 3. Coordinate wiring requirements and electrical characteristics of motors with building electrical system. 4. Provide open dripproof-type motor, and controller with NEMA ICS 6, Type 1 enclosure. 5. Provide totally enclosed, nonventilated or fan-cooled motor, fitted with plugged drain, and controller with NEMA ICS 6, Type 4 enclosure where indicated.
BC&A OVERHEAD COILING DOORS JVWCD PAGE 08331-5 CENTRAL PIPELINE PROJECT H. Remote-Control Station: Provide momentary-contact, three-button control station with push-button controls labeled "Open," "Close," and "Stop."
1. Provide interior units, full-guarded, surface-mounted, heavy-duty type, with general-purpose NEMA ICS 6, Type 1 enclosure.
I. Obstruction Detection Device: Provide each motorized door with indicated external automatic safety sensor capable of protecting full width of door opening. Activation of sensor immediately stops and reverses downward door travel.
1. Sensor Edge: Provide each motorized door with an automatic safety sensor edge, located within astragal or weather stripping mounted to bottom bar. Contact with sensor immediately stops and reverses downward door travel. Connect to control circuit using manufacturer's standard take-up reel or self-coiling cable. a. Provide electrically actuated automatic bottom bar.
J. Limit Switches: Provide adjustable switches, interlocked with motor controls and set to automatically stop door at fully opened and fully closed positions.
K. Provide electric operators with ADA-compliant audible alarm and visual indicator lights.
2.7 FINISHES, GENERAL
A. General: Comply with NAAMM's "Metal Finishes Manual for Architectural and Metal Products" for recommendations for applying and designating finishes.
B. Appearance of Finished Work: Variations in appearance of abutting or adjacent pieces are acceptable if they are within one-half of the range of approved Samples. Noticeable variations in the same piece are not acceptable. Variations in appearance of other components are acceptable if they are within the range of approved Samples and are assembled or installed to minimize contrast.
2.8 STEEL AND GALVANIZED STEEL FINISHES
A. Factory Primer for Field Finish: Manufacturer's standard primer, compatible with field-applied finish according to coating manufacturer's written instructions for cleaning, pretreatment, application, and minimum dry film thickness.
PART 3 – EXECUTION
3.1 INSTALLATION
A. General: Install coiling doors and operating equipment complete with necessary hardware, jamb and head molding strips, anchors, inserts, hangers, and equipment supports.
3.2 ADJUSTING
A. Lubricate bearings and sliding parts; adjust doors to operate easily, free of warp, twist, or distortion and with weathertight fit around entire perimeter.
BC&A OVERHEAD COILING DOORS JVWCD PAGE 08331-6 CENTRAL PIPELINE PROJECT
3.3 STARTUP SERVICES
A. Engage a factory-authorized service representative to perform startup service.
1. Complete installation and startup checks according to manufacturer's written instructions. 2. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment.
3.4 DEMONSTRATION
A. Engage a factory-authorized service representative to train Owner's maintenance personnel to adjust, operate, and maintain overhead coiling doors. Refer to Division 1 Section "Closeout Procedures."
END OF SECTION
BC&A OVERHEAD COILING DOORS JVWCD PAGE 08331-7 CENTRAL PIPELINE PROJECT
SECTION 08711 DOOR HARDWARE (SCHEDULED BY NAMING PRODUCTS)
PART 1 – GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section includes the following:
1. Commercial door hardware for the following: a. Swinging doors. b. Other doors to the extent indicated. 2. Cylinders for doors specified in other Sections. 3. Electrified door hardware.
B. Related Sections include the following:
1. Division 1 Section "LEED Requirements" for LEED certification targets, related LEED requirements, recycled content minima, other LEED criteria and constraints. 2. Information attached for reference, including LEED Checklist for Project building(s), indicating which LEED credits are targeted for attainment. 3. LEED reference documents, not attached but available for use, including the “LEED- New Construction v.2.2 Rating System,” explaining requirements for each prerequisite and credit, and the “LEED-New Construction v2.2 Reference Guide,” detailing requirements and documentation options for application for each prerequisite and credit. 4. Division 8 Section "Steel Doors and Frames" for astragals provided as part of a fire-rated labeled assembly and for door silencers provided as part of the frame. 5. Division 8 Section "Flush Wood Doors" for astragals provided as part of a fire-rated labeled assembly. 6. Division 8 Section "Access Doors" for access door hardware, except cylinders. 7. Division 8 Section "Entrances and Storefronts" for entrance door hardware, except cylinders.
C. Products furnished, but not installed, under this Section include the following. Coordinating, purchasing, delivering, and scheduling remain requirements of this Section.
1. Cylinders for locks on aluminum and glass entrance doors.
1.3 SUBMITTALS
A. Product Data: Include installation details, material descriptions, dimensions of individual components and profiles, and finishes.
BC&A DOOR HARDWARE (SCHEDULED BY NAMING PRODUCTS) JVWCD PAGE 08711-1 CENTRAL PIPELINE PROJECT B. Shop Drawings: Details of electrified door hardware, indicating the following:
1. Wiring Diagrams: Detail wiring for power, signal, and control systems and differentiate between manufacturer-installed and field-installed wiring. Include the following: a. System schematic. b. Point-to-point wiring diagram. c. Riser diagram. d. Elevation of each door. 2. Detail interface between electrified door hardware and building control system.
C. Samples for Initial Selection: Manufacturer's color charts consisting of units or sections of units showing the full range of colors, textures, and patterns available for each type of door hardware indicated.
D. Door Hardware Schedule: Prepared by or under the supervision of supplier, detailing fabrication and assembly of door hardware, as well as procedures and diagrams. Coordinate the final Door Hardware Schedule with doors, frames, and related work to ensure proper size, thickness, hand, function, and finish of door hardware.
1. Format: Comply with scheduling sequence and vertical format in DHI's "Sequence and Format for the Hardware Schedule." 2. Organization: Organize the Door Hardware Schedule into door hardware sets indicating complete designations of every item required for each door or opening. a. Organize door hardware sets in same order as in the Door Hardware Schedule at the end of Part 3. 3. Content: Include the following information: a. Type, style, function, size, label, hand, and finish of each door hardware item. b. Manufacturer of each item. c. Fastenings and other pertinent information. d. Location of each door hardware set, cross-referenced to Drawings, both on floor plans and in door and frame schedule. e. Explanation of abbreviations, symbols, and codes contained in schedule. f. Mounting locations for door hardware. g. Door and frame sizes and materials. h. Description of each electrified door hardware function, including location, sequence of operation, and interface with other building control systems. 1) Sequence of Operation: Include description of component functions that occur in the following situations: authorized person wants to enter; authorized person wants to exit; unauthorized person wants to enter; unauthorized person wants to exit. 4. Submittal Sequence: Submit initial draft of final schedule along with essential Product Data to facilitate the fabrication of other work that is critical in the Project construction schedule. Submit the final Door Hardware Schedule after Samples, Product Data, coordination with Shop Drawings of other work, delivery schedules, and similar information has been completed and accepted.
E. Keying Schedule: Prepared by or under the supervision of supplier, detailing Owner's final keying instructions for locks. Include schematic keying diagram and index each key set to unique door designations.
BC&A DOOR HARDWARE (SCHEDULED BY NAMING PRODUCTS) JVWCD PAGE 08711-2 CENTRAL PIPELINE PROJECT
F. Maintenance Data: For each type of door hardware to include in maintenance manuals specified in Division 1.
G. Warranties: Special warranties specified in this Section.
1.4 QUALITY ASSURANCE
A. Installer Qualifications: An experienced installer who has completed door hardware similar in material, design, and extent to that indicated for this Project and whose work has resulted in construction with a record of successful in-service performance.
B. Supplier Qualifications: Door hardware supplier with warehousing facilities in Project's vicinity and who is or employs a qualified Architectural Hardware Consultant, available during the course of the Work to consult with Contractor, Architect, and Owner about door hardware and keying.
1. Electrified Door Hardware Supplier Qualifications: An experienced door hardware supplier who has completed projects with electrified door hardware similar in material, design, and extent to that indicated for this Project, whose work has resulted in construction with a record of successful in-service performance, and who is acceptable to manufacturer of primary materials. a. Engineering Responsibility: Prepare data for electrified door hardware, including Shop Drawings, based on testing and engineering analysis of manufacturer's standard units in assemblies similar to those indicated for this Project. 2. Scheduling Responsibility: Preparation of door hardware and keying schedules.
C. Architectural Hardware Consultant Qualifications: A person who is currently certified by the Door and Hardware Institute as an Architectural Hardware Consultant and who is experienced in providing consulting services for door hardware installations that are comparable in material, design, and extent to that indicated for this Project.
D. Source Limitations: Obtain each type and variety of door hardware from a single manufacturer, unless otherwise indicated.
E. Regulatory Requirements: Comply with provisions of the following:
1. Where indicated to comply with accessibility requirements, comply with Americans with Disabilities Act (ADA), "Accessibility Guidelines for Buildings and Facilities (ADAAG)," and ANSI A117.1, as follows: a. Handles, Pulls, Latches, Locks, and other Operating Devices: Shape that is easy to grasp with one hand and does not require tight grasping, tight pinching, or twisting of the wrist. b. Door Closers: Comply with the following maximum opening-force requirements indicated: 1) Interior Hinged Doors: 5 lbf applied perpendicular to door. 2) Fire Doors: Minimum opening force allowable by authorities having jurisdiction. c. Thresholds: Not more than 1/2 inch high. Bevel raised thresholds with a slope of not more than 1:2.
BC&A DOOR HARDWARE (SCHEDULED BY NAMING PRODUCTS) JVWCD PAGE 08711-3 CENTRAL PIPELINE PROJECT 2. Electrified Door Hardware: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction.
F. Fire-Rated Door Assemblies: Provide door hardware for assemblies complying with NFPA 80 that are listed and labeled by a testing and inspecting agency acceptable to authorities having jurisdiction, for fire ratings indicated, based on testing according to NFPA 252.
1. Test Pressure: Test at atmospheric pressure.
G. Keying Conference: Conduct conference at Project site to comply with requirements in Division 1 Section "Project Meetings." Incorporate keying conference decisions into final keying schedule after reviewing door hardware keying system including, but not limited to, the following:
1. Function of building, flow of traffic, purpose of each area, degree of security required, and plans for future expansion. 2. Preliminary key system schematic diagram. 3. Requirements for key control system. 4. Address for delivery of keys.
H. Preinstallation Conference: Conduct conference at Project site to comply with requirements in Division 1 Section "Project Meetings." Review methods and procedures related to electrified door hardware including, but not limited to, the following:
1. Inspect and discuss electrical roughing-in and other preparatory work performed by other trades. 2. Review sequence of operation for each type of electrified door hardware. 3. Review and finalize construction schedule and verify availability of materials, Installer's personnel, equipment, and facilities needed to make progress and avoid delays. 4. Review required testing, inspecting, and certifying procedures.
1.5 DELIVERY, STORAGE, AND HANDLING
A. Inventory door hardware on receipt and provide secure lock-up for door hardware delivered to Project site.
B. Tag each item or package separately with identification related to the final Door Hardware Schedule, and include basic installation instructions with each item or package.
C. Deliver keys to Owner by registered mail or overnight package service.
1.6 COORDINATION
A. Templates: Obtain and distribute to the parties involved templates for doors, frames, and other work specified to be factory prepared for installing door hardware. Check Shop Drawings of other work to confirm that adequate provisions are made for locating and installing door hardware to comply with indicated requirements.
BC&A DOOR HARDWARE (SCHEDULED BY NAMING PRODUCTS) JVWCD PAGE 08711-4 CENTRAL PIPELINE PROJECT B. Electrical System Roughing-in: Coordinate layout and installation of electrified door hardware with connections to power supplies and building control system.
1.7 WARRANTY
A. General Warranty: Special warranties specified in this Article shall not deprive Owner of other rights Owner may have under other provisions of the Contract Documents and shall be in addition to, and run concurrent with, other warranties made by Contractor under requirements of the Contract Documents.
B. Special Warranty: Written warranty, executed by manufacturer agreeing to repair or replace components of door hardware that fail in materials or workmanship within specified warranty period. Failures include, but are not limited to, the following:
1. Structural failures including excessive deflection, cracking, or breakage. 2. Faulty operation of operators and door hardware. 3. Deterioration of metals, metal finishes, and other materials beyond normal weathering.
C. Warranty Period: Three years from date of Substantial Completion, unless otherwise indicated.
D. Warranty Period for Manual Closers: 10 years from date of Substantial Completion.
1.8 MAINTENANCE SERVICE
A. Maintenance Tools and Instructions: Furnish a complete set of specialized tools and maintenance instructions as needed for Owner's continued adjustment, maintenance, and removal and replacement of door hardware.
PART 2 – PRODUCTS
2.1 SCHEDULED DOOR HARDWARE
A. General: Provide door hardware for each door to comply with requirements in this Section, and the Door Hardware Schedule at the end of Part 3.
1. Door Hardware Sets: Provide quantity, item, size, finish or color indicated, and products equivalent in function and comparable in quality to named products. 2. Sequence of Operation: Provide electrified door hardware function, sequence of operation, and interface with other building control systems indicated.
B. Designations: Requirements for design, grade, function, finish, size, and other distinctive qualities of each type of door hardware are indicated in the Door Hardware Schedule at the end of Part 3. Products are identified by using door hardware designations, as follows:
1. Named Manufacturer's Products: Product designation and manufacturer are listed for each door hardware type required for the purpose of establishing minimum requirements. Manufacturers' names are abbreviated in the Door Hardware Schedule.
BC&A DOOR HARDWARE (SCHEDULED BY NAMING PRODUCTS) JVWCD PAGE 08711-5 CENTRAL PIPELINE PROJECT 2.2 HINGES AND PIVOTS
A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:
1. Hinges: a. Bommer Industries, Inc. (BI). b. Hager Companies (HAG). c. Ives: H. B. Ives (IVS). d. McKinney Products Company; Div. of ESSEX Industries, Inc. (MCK). e. Stanley Commercial Hardware; Div. of The Stanley Works (STH).
B. Quantity: Provide the following, unless otherwise indicated:
1. Two Hinges: For doors with heights up to 60 inches. 2. Three Hinges: For doors with heights 61 to 90 inches. 3. Four Hinges: For doors with heights 91 to 120 inches. 4. For doors with heights more than 120 inches, provide 4 hinges, plus 1 hinge for every 30 inches of door height greater than 120 inches.
C. Template Requirements: Except for hinges and pivots to be installed entirely (both leaves) into wood doors and frames, provide only template-produced units.
D. Hinge Base Metal: Unless otherwise indicated, provide the following:
1. Interior Hinges: Brass, with stainless-steel pin body and brass protruding heads. 2. Hinges for Fire-Rated Assemblies: Steel, with steel pin.
E. Hinge Options: Comply with the following where indicated in the Door Hardware Schedule or on Drawings:
1. Nonremovable Pins: Provide set screw in hinge barrel that, when tightened into a groove in hinge pin, prevents removal of pin while door is closed; for the following applications: a. Outswinging exterior doors. b. Outswinging corridor doors with locks. 2. Corners: Square.
F. Fasteners: Comply with the following:
1. Machine Screws: For metal doors and frames. Install into drilled and tapped holes. 2. Wood Screws: For wood doors and frames. 3. Threaded-to-the-Head Wood Screws: For fire-rated wood doors. 4. Screws: Phillips flat-head screws; machine screws (drilled and tapped holes) for metal doors, wood screws for wood doors and frames. Finish screw heads to match surface of hinges.
BC&A DOOR HARDWARE (SCHEDULED BY NAMING PRODUCTS) JVWCD PAGE 08711-6 CENTRAL PIPELINE PROJECT 2.3 LOCKS AND LATCHES
A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:
1. Mechanical Locks and Latches: a. Schlage Lock Company; an Ingersoll-Rand Company (SCH). 2. Electromechanical Locks and Latches: a. Best Lock Corporation (BLC). b. Locknetics Security Engineering; a Harrow Company (LSE). c. Schlage Lock Company; an Ingersoll-Rand Company (SCH).
B. Bored Locks: BHMA Grade 1; Series 4000.
C. Certified Products: Provide door hardware listed in the following BHMA directories:
1. Mechanical Locks and Latches: BHMA's "Directory of Certified Locks & Latches."
D. Lock Trim: Comply with the following:
1. Lever: Cast. 2. Knob: Wrought. 3. Escutcheon (Rose): Wrought. 4. Dummy Trim: Match lever lock trim and escutcheons. 5. Lockset Designs: Provide the lockset design designated below or, if sets are provided by another manufacturer, provide designs that match those designated: a. Bored Locks: Provide design indicated in schedules.
E. Lock Functions: Function numbers and descriptions indicated in the Door Hardware Schedule comply with the following:
1. Mortise Locks: BHMA A156.13.
F. Lock Throw: Comply with testing requirements for length of bolts to comply with labeled fire door requirements, and as follows:
1. Mortise Locks: Minimum 3/4-inch latchbolt throw. 2. Deadbolts: Minimum 1-inch bolt throw.
G. Backset: 2-3/4 inches, unless otherwise indicated.
2.4 ELECTRIFIED LOCKS AND LATCHES
A. Electromechanical Locks: Motor-operated locks of types and grades indicated; with electromagnet attached to frame and strike plate attached to door. Comply with the following:
1. BHMA Grade: Grade 1.
BC&A DOOR HARDWARE (SCHEDULED BY NAMING PRODUCTS) JVWCD PAGE 08711-7 CENTRAL PIPELINE PROJECT 2.5 DOOR BOLTS
A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:
1. Flush Bolts: a. Glynn-Johnson; an Ingersoll-Rand Company (GJ). b. Ives: H. B. Ives (IVS). c. NT Quality Hardware; an Ingersoll-Rand Company (NTQ). d. Rockwood Manufacturing Company (RM).
B. Flush Bolts: BHMA Grade 1, designed for mortising into door edge.
C. Bolt Throw: Comply with testing requirements for length of bolts to comply with labeled fire door requirements, and as follows:
1. Half-Round Surface Bolts: Minimum 7/8-inch throw. 2. Interlocking Surface Bolts: Minimum 15/16-inch throw. 3. Fire-Rated Surface Bolts: Minimum 1-inch throw; listed and labeled for fire-rated doors. 4. Mortise Flush Bolts: Minimum 3/4-inch throw.
2.6 EXIT DEVICES
A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:
1. Sargent Manufacturing Company; Div. of ESSEX Industries, Inc. (SGT). 2. Precision Hardware, Inc. (PH). 3. Von Duprin; an Ingersoll-Rand Company (VD).
B. Certified Products: Provide exit devices listed in BHMA's "Directory of Certified Exit Devices."
C. Panic Exit Devices: Listed and labeled by a testing and inspecting agency acceptable to authorities having jurisdiction, for panic protection, based on testing according to UL 305.
D. Fire Exit Devices: Complying with NFPA 80 that are listed and labeled by a testing and inspecting agency acceptable to authorities having jurisdiction, for fire and panic protection, based on testing according to UL 305 and NFPA 252.
E. Dummy Push Bar: Nonfunctioning push bar matching functional push bar.
1. Operation: Rigid.
F. Outside Trim: Lever or Lever with cylinder; material and finish to match locksets, unless otherwise indicated.
1. Match design for locksets and latchsets, unless otherwise indicated.
BC&A DOOR HARDWARE (SCHEDULED BY NAMING PRODUCTS) JVWCD PAGE 08711-8 CENTRAL PIPELINE PROJECT G. Through Bolts: For exit devices and trim on metal doors, non-fire-rated wood doors, and fire-rated wood doors.
2.7 CYLINDERS AND KEYING
A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:
1. Cylinders: Same manufacturer as for locks and latches. 2. Key Control Systems: a. Key Control Systems, Inc. (KCS). b. Major Metalfab Co. (MM). c. Sargent Manufacturing Company; Div. of ESSEX Industries, Inc. (SGT). d. Sunroc Corporation (SUN).
B. Cylinders: Manufacturer's standard tumbler type, constructed from brass or bronze, stainless steel, or nickel silver, and complying with the following:
1. Number of Pins: Seven. 2. Mortise Type: Threaded cylinders with rings and straight- or clover-type cam. 3. Rim Type: Cylinders with back plate, flat-type vertical or horizontal tailpiece, and raised trim ring.
C. Permanent Cores: Manufacturer's standard; finish face to match lockset; complying with the following:
1. Removable Cores: Core insert, removable by use of a special key, and for use with only the core manufacturer's cylinder and door hardware.
D. Construction Keying: Comply with the following:
1. Construction Cores: Provide construction cores that are replaceable by permanent cores. Provide 10 construction master keys. a. Replace construction cores with permanent cores, as directed by Owner.
E. Keying System: Unless otherwise indicated, provide a factory-registered keying system complying with the following requirements:
1. Grand Master Key System: Cylinders are operated by a change key, a master key, and a grand master key.
F. Keys: Provide nickel-silver keys complying with the following:
1. Stamping: Permanently inscribe each key with a visual key control number and include the following notation: a. Notation: "DO NOT DUPLICATE." 2. Quantity: In addition to one extra blank key for each lock, provide the following: a. Cylinder Change Keys: Three. b. Master Keys: Five. c. Grand Master Keys: Five.
BC&A DOOR HARDWARE (SCHEDULED BY NAMING PRODUCTS) JVWCD PAGE 08711-9 CENTRAL PIPELINE PROJECT G. Key Control System: BHMA Grade 1 system, including key-holding hooks, labels, two sets of key tags with self-locking key holders, key-gathering envelopes, and temporary and permanent markers. Contain system in metal cabinet with baked-enamel finish.
1. Wall-Mounted Cabinet: Cabinet with hinged-panel door equipped with key-holding panels and pin-tumbler cylinder door lock. 2. Capacity: Able to hold keys for 150 percent of the number of locks. 3. Cross-Index System: Set up by key control manufacturer, complying with the following: a. Card Index: Furnish four sets of index cards for recording key information. Include three receipt forms for each key-holding hook.
2.8 STRIKES
A. Strikes: Provide manufacturer's standard strike with strike box for each latch or lock bolt, with curved lip extended to protect frame, finished to match door hardware set, unless otherwise indicated, and as follows:
1. Flat-Lip Strikes: For locks with three-piece antifriction latchbolts, as recommended by manufacturer. 2. Extra-Long-Lip Strikes: For locks used on frames with applied wood casing trim.
B. Dustproof Strikes: BHMA Grade 1.
2.9 OPERATING TRIM
A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:
1. Hager Companies (HAG). 2. Ives: H. B. Ives (IVS). 3. NT Quality Hardware; an Ingersoll-Rand Company (NTQ). 4. Rockwood Manufacturing Company (RM). 5. Stanley Commercial Hardware; Div. of The Stanley Works (STH).
B. Materials: Fabricate from stainless steel, unless otherwise indicated.
C. Push-Pull Design: As illustrated on Drawings.
2.10 ACCESSORIES FOR PAIRS OF DOORS
A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:
1. Coordinators: a. Glynn-Johnson; an Ingersoll-Rand Company (GJ). b. Hager Companies (HAG). c. Ives: H. B. Ives (IVS). d. Rockwood Manufacturing Company (RM).
BC&A DOOR HARDWARE (SCHEDULED BY NAMING PRODUCTS) JVWCD PAGE 08711-10 CENTRAL PIPELINE PROJECT 2. Removable Mullions: a. Sargent Manufacturing Company; Div. of ESSEX Industries, Inc. (SGT). b. Von Duprin; an Ingersoll-Rand Company (VD).
B. Fire-Exit Removable Mullions: Provide removable mullions for use with fire exit devices complying with NFPA 80 that are listed and labeled by a testing and inspecting agency acceptable to authorities having jurisdiction, for fire and panic protection, based on testing according to UL 305 and NFPA 252. Mullions shall be used only with exit devices for which they have been tested.
2.11 CLOSERS
A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:
1. Surface-Mounted Closers: a. LCN Closers; an Ingersoll-Rand Company (LCN).
B. Certified Products: Provide door closers listed in BHMA's "Directory of Certified Door Closers."
C. Hold-Open Closers/Detectors: Coordinate and interface integral smoke detector and closer device with fire alarm system.
D. Size of Units: Unless otherwise indicated, comply with manufacturer's written recommendations for size of door closers depending on size of door, exposure to weather, and anticipated frequency of use. Provide factory-sized closers, adjustable to meet field conditions and requirements for opening force.
2.12 PROTECTIVE TRIM UNITS
A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:
1. Metal Protective Trim Units: a. Hager Companies (HAG). b. Ives: H. B. Ives (IVS). c. NT Quality Hardware; an Ingersoll-Rand Company (NTQ). d. Rockwood Manufacturing Company (RM).
B. Materials: Fabricate protection plates from the following:
1. Stainless Steel: 0.050 inch thick; beveled top and 2 sides.
C. Fasteners: Provide manufacturer's standard exposed fasteners for door trim units consisting of either machine or self-tapping screws.
D. Furnish protection plates sized 2 inches less than door width on push side and 1/2 inch less than door width on pull side, by height specified in Door Hardware Schedule.
BC&A DOOR HARDWARE (SCHEDULED BY NAMING PRODUCTS) JVWCD PAGE 08711-11 CENTRAL PIPELINE PROJECT
2.13 STOPS AND HOLDERS
A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:
1. Hager Companies (HAG). 2. Ives: H. B. Ives (IVS). 3. NT Quality Hardware; an Ingersoll-Rand Company (NTQ). 4. Rockwood Manufacturing Company (RM).
B. Electromagnetic Door Holders for Labeled Fire Door Assemblies: Coordinate with fire detectors and interface with fire alarm system.
C. Floor Stops: For doors, unless wall or other type stops are scheduled or indicated. Do not mount floor stops where they will impede traffic.
1. Where floor or wall stops are not appropriate, provide overhead holders.
D. Silencers for Wood Door Frames: BHMA Grade 1; neoprene or rubber, minimum 5/8 by 3/4 inch; fabricated for drilled-in application to frame.
E. Silencers for Metal Door Frames: BHMA Grade 1; neoprene or rubber, minimum diameter 1/2 inch; fabricated for drilled-in application to frame.
2.14 DOOR GASKETING
A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:
1. Door Gasketing: a. Hager Companies (HAG). b. National Guard Products, Inc. (NGP). c. Pemko Manufacturing Co., Inc. (PEM). d. Zero International, Inc. (ZRO).
B. General: Provide continuous weather-strip gasketing on exterior doors and provide smoke, light, or sound gasketing on interior doors where indicated or scheduled. Provide noncorrosive fasteners for exterior applications and elsewhere as indicated.
1. Perimeter Gasketing: Apply to head and jamb, forming seal between door and frame. 2. Meeting Stile Gasketing: Fasten to meeting stiles, forming seal when doors are closed. 3. Door Bottoms: Apply to bottom of door, forming seal with threshold when door is closed.
C. Air Leakage: Not to exceed 0.50 cfm per foot of crack length for gasketing other than for smoke control, as tested according to ASTM E 283.
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D. Smoke-Labeled Gasketing: Assemblies complying with NFPA 105 that are listed and labeled by a testing and inspecting agency acceptable to authorities having jurisdiction, for smoke-control ratings indicated, based on testing according to UL 1784.
1. Provide smoke-labeled gasketing on 20-minute-rated doors and on smoke-labeled doors.
E. Fire-Labeled Gasketing: Assemblies complying with NFPA 80 that are listed and labeled by a testing and inspecting agency acceptable to authorities having jurisdiction, for fire ratings indicated, based on testing according to UL 10B or NFPA 252.
F. Replaceable Seal Strips: Provide only those units where resilient or flexible seal strips are easily replaceable and readily available from stocks maintained by manufacturer.
G. Gasketing Materials: Comply with ASTM D 2000 and AAMA 701/702.
2.15 THRESHOLDS
A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:
1. Hager Companies (HAG). 2. National Guard Products, Inc. (NGP). 3. Pemko Manufacturing Co., Inc. (PEM). 4. Reese Enterprises, Inc. (RE).
2.16 FABRICATION
A. Manufacturer's Nameplate: Do not provide manufacturers' products that have manufacturer's name or trade name displayed in a visible location (omit removable nameplates) except in conjunction with required fire-rated labels and as otherwise approved by Architect.
1. Manufacturer's identification will be permitted on rim of lock cylinders only.
B. Base Metals: Produce door hardware units of base metal, fabricated by forming method indicated, using manufacturer's standard metal alloy, composition, temper, and hardness. Furnish metals of a quality equal to or greater than that of specified door hardware units and BHMA A156.18 for finishes. Do not furnish manufacturer's standard materials or forming methods if different from specified standard.
C. Fasteners: Provide door hardware manufactured to comply with published templates generally prepared for machine, wood, and sheet metal screws. Provide screws according to commercially recognized industry standards for application intended. Provide Phillips flat-head screws with finished heads to match surface of door hardware, unless otherwise indicated.
1. Concealed Fasteners: For door hardware units that are exposed when door is closed, except for units already specified with concealed fasteners. Do not use
BC&A DOOR HARDWARE (SCHEDULED BY NAMING PRODUCTS) JVWCD PAGE 08711-13 CENTRAL PIPELINE PROJECT through bolts for installation where bolt head or nut on opposite face is exposed unless it is the only means of securely attaching the door hardware. Where through bolts are used on hollow door and frame construction, provide sleeves for each through bolt. 2. Steel Machine or Wood Screws: For the following fire-rated applications: a. Mortise hinges to doors. b. Strike plates to frames. c. Closers to doors and frames. 3. Steel Through Bolts: For the following fire-rated applications, unless door blocking is provided: a. Surface hinges to doors. b. Closers to doors and frames. c. Surface-mounted exit devices. 4. Spacers or Sex Bolts: For through bolting of hollow metal doors. 5. Fasteners for Wood Doors: Comply with requirements of DHI WDHS.2, "Recommended Fasteners for Wood Doors."
2.17 FINISHES
A. Standard: Comply with BHMA A156.18.
B. Protect mechanical finishes on exposed surfaces from damage by applying a strippable, temporary protective covering before shipping.
C. Appearance of Finished Work: Variations in appearance of abutting or adjacent pieces are acceptable if they are within one-half of the range of approved Samples. Noticeable variations in the same piece are not acceptable. Variations in appearance of other components are acceptable if they are within the range of approved Samples and are assembled or installed to minimize contrast.
PART 3 – EXECUTION
3.1 EXAMINATION
A. Examine doors and frames, with Installer present, for compliance with requirements for installation tolerances, labeled fire door assembly construction, wall and floor construction, and other conditions affecting performance.
B. Examine roughing-in for electrical power systems to verify actual locations of wiring connections before electrified door hardware installation.
C. Proceed with installation only after unsatisfactory conditions have been corrected.
3.2 PREPARATION
A. Steel Doors and Frames: Comply with DHI A115 series.
1. Surface-Applied Door Hardware: Drill and tap doors and frames according to SDI 107.
B. Wood Doors: Comply with DHI A115-W series.
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3.3 INSTALLATION
A. Mounting Heights: Mount door hardware units at heights indicated in following applicable publications, unless specifically indicated or required to comply with governing regulations:
1. Standard Steel Doors and Frames: DHI's "Recommended Locations for Architectural Hardware for Standard Steel Doors and Frames." 2. Wood Doors: DHI WDHS.3, "Recommended Locations for Architectural Hardware for Wood Flush Doors."
B. Install each door hardware item to comply with manufacturer's written instructions. Where cutting and fitting are required to install door hardware onto or into surfaces that are later to be painted or finished in another way, coordinate removal, storage, and reinstallation of surface protective trim units with finishing work specified in Division 9 Sections. Do not install surface-mounted items until finishes have been completed on substrates involved.
1. Set units level, plumb, and true to line and location. Adjust and reinforce attachment substrates as necessary for proper installation and operation. 2. Drill and countersink units that are not factory prepared for anchorage fasteners. Space fasteners and anchors according to industry standards.
C. Key Control System: Place keys on markers and hooks in key control system cabinet, as determined by final keying schedule.
D. Thresholds: Set thresholds for exterior and acoustical doors in full bed of sealant complying with requirements specified in Division 7 Section "Joint Sealants."
3.4 ADJUSTING
A. Initial Adjustment: Adjust and check each operating item of door hardware and each door to ensure proper operation or function of every unit. Replace units that cannot be adjusted to operate as intended. Adjust door control devices to compensate for final operation of heating and ventilating equipment and to comply with referenced accessibility requirements.
1. Electric Strikes: Adjust horizontal and vertical alignment of keeper to properly engage lock bolt. 2. Door Closers: Adjust sweep period so that, from an open position of 70 degrees, the door will take at least 3 seconds to move to a point 3 inches from the latch, measured to the leading edge of the door.
B. Six-Month Adjustment: Approximately six months after date of Substantial Completion, Installer shall perform the following:
1. Examine and readjust each item of door hardware as necessary to ensure function of doors, door hardware, and electrified door hardware. 2. Consult with and instruct Owner's personnel on recommended maintenance procedures. 3. Replace door hardware items that have deteriorated or failed due to faulty design, materials, or installation of door hardware units.
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A. Clean adjacent surfaces soiled by door hardware installation.
B. Clean operating items as necessary to restore proper function and finish.
C. Provide final protection and maintain conditions that ensure door hardware is without damage or deterioration at time of Substantial Completion.
3.6 DEMONSTRATION
A. Engage a factory-authorized service representative to train Owner's maintenance personnel to adjust, operate, and maintain door hardware and door hardware finishes.
3.7 DOOR HARDWARE SCHEDULE
A. Refer to drawings.
END OF SECTION
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DIVISION 9 FINISHES
SECTION 09900 PAINTING
PART 1 GENERAL
1.01 WORK INCLUDED
A. This section covers surface preparation, furnishing, and application of architectural paint and special protective coatings, complete.
B. Shop or existing surface preparation methods, cleanliness, and existing paint, rust, and mill scale removal is not known nor documented. Contractor shall be solely responsible for determining work effort, abrasive blast requirements, and any other factors that may affect work productivity as required to provide the specified surface preparation cleanliness; regardless of prior system preparation or coating application.
1.02 ABBREVIATIONS
ANSI American National Standards Institute AWWA American Water Works Association FRP Fiberglass Reinforced Plastic HCl Hydrochloric Acid MDFT Minimum Dry Film Thickness MDFTPC Minimum Dry Film Thickness Per Coat mil Thousandths of an Inch MIL-P Military Specification – Paint OSHA Occupational Safety and Health Act PSDS Paint System Data Sheet SFPG Square Feet Per Gallon SFPGPC Square Feet Per Gallon Per Coat SP Surface Preparation SSPC Steel Structures Painting Council
1.03 SUBMITTALS
A. Product Data: Furnish the following Data Sheets: 1. For each paint system used herein, furnish a Paint System Data Sheet (PSDS), Technical Data Sheets, and paint colors available (where applicable) for each product used in the paint system, except for products applied by equipment manufacturers. A sample PSDS form is appended at the end of this section. 2. The required information shall be submitted on a system-by-system basis. 3. The Contractor shall also provide copies of the paint system submittals to the coating applicator. 4. Indiscriminate submittal of manufacturer's literature only is not acceptable.
B. Where ANSI/NSF Standard 60 and 61 approval is required, submit ANSI/NSF certification letter for each coating in the system indicating product application limits
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on size of tank or piping, dry film thickness, number of coats, specific product tested, colors certified, and approved additives.
C. Provide TCLP test data for lead and other regulated heavy metals in non- recyclable, slag type abrasive blast media to be used on the project. Acceptable abrasive test data shall indicate the abrasive manufacturer, location of manufacture, and media gradation and type. Surface preparation will not be permitted to begin until acceptable test data has been submitted.
D. Quality Control Submittals: Furnish the following: 1. Applicator's Experience: List of references substantiating the requirements as specified. 2. Factory Applied Coatings: Manufacturer's certification stating factory applied coating systems meets or exceeds requirements specified herein. 3. If the manufacturer of finish coating differs from that of shop primer, provide both manufacturer's written confirmation that materials are compatible.
1.04 QUALITY ASSURANCE
A. The paint manufacturer shall provide a representative to visit the jobsite at intervals during surface preparation and painting as may be required for product application quality assurance, and to determine compliance with manufacturer's instructions and these Specifications, and as may be necessary to resolve field problems attributable to, or associated with, the manufacturer's products furnished under this Contract.
B. Applicator's Experience: Minimum of 5 years' practical experience in application of specified products. Submit a list of recent projects and names of references for those projects. The Engineer will waive the requirement for five years experience, when at the discretion of the Engineer, the applicators’ experience and capabilities meet the intent of the experience requirement.
C. Continuity of Contractor: Contractor's site supervisor shall be coordinated with the ENGINEER. Any replacement of the supervisor on site will require notification of ENGINEER 72 hours in advance, and will be subject to approval by the OWNER.
D. Inspection: 1. Inspect and provide substrate surfaces prepared in accordance with these specifications and the printed directions and recommendations of paint manufacturer whose product is to be applied. 2. Provide ENGINEER minimum 3 days' advance notice prior to start of surface preparation work or coating application work. 3. Perform work only in the presence of ENGINEER, unless ENGINEER grants prior approval to perform such work in Engineer’s absence. Approval to perform work in the Engineer’s absence is limited to the current day unless specifically noted to extend beyond the completion of the workday. 4. Inspection by the ENGINEER, or the waiver of inspection of any particular portion of the work, shall not be construed to relieve the Contractor of responsibility to perform the work in accordance with these specifications.
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1.05 PAINT DELIVERY, STORAGE, AND HANDLING
A. Delivered paint to the project site in unopened containers that plainly show, at the time of use, the designated name, date of manufacture, color, and name of manufacturer.
B. Stored paints in a suitable protected area that is heated or cooled as required to maintain temperatures within the range recommended by the paint manufacturer.
C. Shipping: 1. Where precoated items are to be shipped to the jobsite, protect coating from damage. Batten coated items to prevent abrasion. 2. Use nonmetallic or padded slings and straps in handling. 3. Items will be rejected for excessive damage.
1.06 WARRANTY
A. The Contractor and coating manufacturer shall jointly and severally warrant to the Owner and guarantee the work under this section against defective workmanship and materials for a period of 2 year(s) commencing on the date of final acceptance of the work.
PART 2 PRODUCTS
2.01 PAINT AND COATINGS MANUFACTURERS
A. A manufacturer letter code as follows will be found following the generic descriptions of materials outlined in the Specifications. Address is that of the general offices. Contact these offices for information regarding the location of representative nearest the project site.
B. MANUFACTURER CODE A - COATINGS MANUFACTURERS (Able to supply most heavy-duty industrial coatings and architectural paints):
1. Carboline Coatings Company, St. Louis, MO. 2. ICI Devoe Coatings Company, Louisville, KY. 3. International Coatings, 4. Pittsburgh Paints (PPG), Pittsburgh, PA. 5. Sherwin Williams, Cleveland, OH 6. Tnemec Coatings, Kansas City, MO
2.02 PAINT MATERIALS
A. Products shall meet federal, state, and local requirements limiting the emission of volatile organic compounds. Specific information may be secured through the local office of the Air Pollution Control Officer.
B. Materials Including Primer and Finish Coats: Produced by same paint manufacturer.
C. Thinners, Cleaners, Driers, and Other Additives: As recommended by paint manufacturer of the particular coating. Where coatings are required to meet
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ANSI/NSF Standard 60 and 61, addition of thinners, driers, and other paint additives not approved under the ANSI/NSF certification letter will not be permitted without written approval from the ENGINEER.
D. Paint products are listed according to their approximate order of appearance in the paint systems. The letter designating the manufacturer code refers to Article PAINT AND COATING MANUFACTURERS.
Product Definition Potable Grade, Amine or polyamine epoxy coating, approved for potable water Polyamide contact in conformance to ANSI/NSF Standard 60 and 61, suitable Epoxy Coatings for the application temperatures and conditions. MANUFACTURER CODE: A Polyamide, Epoxy Polyamine or polyamide epoxy, two parts, suitable for immersion service, 75% volume solids minimum, capable of 4 to 8 MDFT per coat. MANUFACTURER CODE: A Poysiloxane Acrylic polysiloxane hybrid coating, single component, suitable for shop or field application at 32 degrees F, minimum, recoat window of not less than 12 months with preference for products with unlimited overcoat capability, solids content of 85% minimum, high gloss, and tintable colors. Tinted colors shall be capable of storage for 30 days or longer prior to application. Coating shall be capable of spray, roller, or brush application on all metal substrates and specified prime and intermediate coats. MANUFACTURER CODE: A Polyamide, Anti-Corrosive, Polyamide or Polyamine epoxy primer, two parts, containing rust- Epoxy Primer inhibitive pigments MANUFACTURER CODE: A Organic Zinc Rich Primer Converted epoxy, epoxy/phenolic or urethane type, minimum 10 lbs.; metallic zinc content per gallon MANUFACTURER CODE: A Inorganic Zinc Primer Solvent or water based, 14 lbs. metallic zinc content per gallon minimum; unlimited recoat window, follow manufacturer's recommendation for top coating. MANUFACTURER CODE: A Rust-Inhibitive Primer Single-package steel primers with anti-corrosive pigment loading; may be alkyd, vinyl, epoxy ester, chlorinated rubber. MANUFACTURER CODE: A-B Alkyd Enamel Optimum quality, gloss finish, medium long oil. MANUFACTURER CODE: A-B Wash Primer Vinyl butyral acid or equivalent coating for enhancing finish coat adhesion to galvanized steel surfaces. MANUFACTURER CODE: A Polyurethane Enamel Two-component, aliphatic or acrylic based polyurethane; high gloss finish, suitable for continuous dry service at 200 degrees F without discoloration or peeling. MANUFACTURER CODE: A Fusion Bonded Coating 100% solids, thermosetting, fusion bonded, dry powder epoxy or polyurethane resin, suitable for this intended service. MANUFACTURER CODE: E
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2.03 COLORS
A. Provide as selected by the Owner.
B. Formulated with colorants free of lead, lead compounds, or other materials which might be affected by the presence of hydrogen sulfide or other gas likely to be present at the project.
C. Proprietary identification of colors is for identification only. Any authorized manufacturer may supply matches.
D. Equipment Colors:
1. Equipment shall be meant to include the machinery or vessel itself plus the structural supports and fasteners and attached electrical conduits. 2. Paint non-submerged portions of equipment in the same color as the process piping it serves, except as itemized below: a. Dangerous parts of equipment and machinery: OSHA Orange b. Fire protection equipment and Apparatus: OSHA Red c. Radiation hazards: OSHA Purple d. Physical hazards in normal operating area: OSHA Yellow 3. Fiberglass reinforced plastic (FRP) equipment with an integral colored gel coat does not require painting, provided the color is as specified.
E. Pipe Identification Painting:
1. Color code non-submerged metal piping except electrical conduit. Paint fittings and valves the same color as the pipe. 2. Piping color coding: In accordance with the Piping Schedule as shown. 3. On exposed stainless steel piping, apply color 24 inches in length along pipe axis at all connections to equipment, valves, or branch fittings, at wall boundaries, and at intervals along the piping not greater than 9 feet on center, with identification labels applied to each exposed run of pipe as specified herein. 4. Pipe supports: Mild steel, painted No. 70 light gray as specified in ANSI Z35.1. 5. Fiberglass reinforced plastic (FRP) pipe and polyvinyl chloride (PVC) pipe located outside of buildings and enclosed structures will not require painting, except as noted.
F. Labels for Piping: 1. Identification labels shall bear the full piping system name as specified in the Piping Schedule shown. 2. Install separate flow directional arrows with each label. 3. Include black lettering on OSHA safety yellow self-adhesive vinyl or vinyl cloth. 4. Lettering height: Meet ANSI A13.1. 5. Label and Adhesive: Long lasting, resistant to moisture, oils, solvents, and weathering, meeting OSHA requirements. 6. Locate labels at all connections to equipment, valves, or branch fittings, at wall boundaries, and at intervals along the piping not greater than 18 feet on center, with at least one label applied to each exposed run of pipe.
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7. Manufacturers: a. W. H. Brady Co., Milwaukee, WI b. Seton Nameplate Corp., New Haven, CT c. or Equal. 8. Pipe System and Color:
Compressed Air Federal Safety Purple Drains Black Fluoride Natural Gas Federal Safety yellow Potable Water Light Blue Sample Medium Green
2.04 QA/QC TESTING AND INSPECTION
A. General 1. Applicator shall inspect and test the coating system in accordance with referenced standards and these specifications, whichever is more stringent. 2. Quality control testing as specified in AWWA standards are minimum industry standards and it is the intent of this specification to provide a higher level of quality control for the objective of achieving maximum coating performance. 3. If any conflict between this specification and referenced standards occurs, the more stringent requirement shall apply and any interpretation of this requirement or results shall be with the objective of achieving maximum coating performance. 4. The frequency of the testing shall be determined by the applicator, but shall not be less than the requirements of this specification.
B. Surface Profile Testing 1. Surface profile of abrasive blasted surfaces to be tested with “Press-O-Film” tester tape or equivalent in accordance with NACE RP287. 2. Tester tape shall be suitable for the intended profile height. 3. Profile shall be measured to a minimum tolerance of 0.1 mils, maximum. 4. Electronic surface profilometer shall be used, where deemed necessary, to verify tester tape measurements.
C. Adhesion testing: As specified in Section 09910, where directed by the Engineer for assessing coating application problems.
D. Holiday Testing 1. Holiday tests on polyurethane coatings or linings will be conducted on the completed coating or lining after cure or 24-hours, whichever is less, using a high voltage spark test in accordance with NACE SP-0188 and these specifications. 2. Coating thickness used for high voltage holiday testing setting shall be the average dry coating thickness.
E. Dry Film Thickness Testing 1. Coatings shall be tested for dry film thickness using a properly calibrated magnetic pull off, eddy current, or ultrasonic equipment.
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2. Coating thickness measurements shall be conducted as necessary and without limitation. Testing conformance to the requirements of SSPC PA-2 is specifically excluded from this specification.
PART 3 EXECUTION
3.01 GENERAL
A. The intention of this specification is for all existing and new, interior and exterior surfaces are painted, whether specifically mentioned or not, except as modified herein. Concealed structural steel surfaces shall receive prime coat only unless modified herein. Exterior concrete surfaces will not be painted unless specifically indicated hereinafter.
B. Surface preparation and coating application shall be in conformance with these specifications and the coating manufacturer’s written product data sheets and written recommendations of the manufacturer’s technical representative. Where conflicts occur between the manufacturer’s recommendations and these specifications, the more stringent of the two shall apply unless otherwise approved by the Engineer.
C. For coatings subject to immersion, obtain full cure for completed system. Consult coatings manufacturer's written instructions for these requirements. Do not immerse coating for any purpose until completion of curing cycle.
3.02 REGULATORY REQUIREMENTS
A. Meet federal, state, and local requirements limiting the emission of volatile organic compounds and worker exposures.
B. Protect workers and comply with applicable federal, state, and local air pollution and environmental regulations for surface preparation, blast cleaning, disposition of spent aggregate and debris, coating application and dust prevention including, but not limited to the following Acts, Regulations, Standards, and Guidelines:
1. Clean Air Act 2. National Ambient Air Quality Standard 3. Resource Conservation and Recovery Act (RCRA)
C. Comply with applicable federal, state, and local regulations for confined space entry.
D. Provide and operate equipment that meets explosion proof requirements.
3.03 ENVIRONMENTAL CONDITIONS
A. Do not perform abrasive blast cleaning whenever the relative humidity exceeds 85 percent, whenever surface temperature is less than 5 degrees F above the dew point of the ambient air.
B. Surface preparation power tools and blast equipment shall contain dust collection equipment that will prevent discharge of dust particles into the atmosphere.
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C. Do not apply paint when: 1. Surface temperatures exceeds the maximum or minimum temperature recommended by the paint manufacturer, 2. In dust, smoke-laden atmosphere, damp or humid weather, or under conditions which could cause icing on the metal surface. 3. When it is expected that surface temperatures will drop below 5 degrees above dew point within 8 hours after application of coating.
3.04 DEHUMIDIFICATION
A. Where environmental conditions cannot be met or controlled, CONTRACTOR shall provide and operate desiccant dehumidification equipment to maintain environmental conditions for 24 hours a day during abrasive blasting and coating application and cure. Liquid, granular, or loose lithium chloride drying systems will not be acceptable.
B. CONTRACTOR shall provide dehumidification equipment sized to maintain dew point temperature 17 degrees or more below surface temperature of metal surfaces to be cleaned and coated. System shall provide ventilation within the environmentally controlled areas as required for the following requirements: 1. One air exchange per hour, minimum, 2. Maintenance of personnel exposures limits (PEL) at 50 percent of OSHA PEL limits for all chemicals used in the performance of the work, and 3. Maintenance of lower explosive limits (LEL) to less than 50 percent of the most volatile solvent used in the performance of the work.
C. Dehumidification equipment type, size, air flow, and power requirements shall be designed by a qualified company knowledgeable in dehumidification equipment, and its operation based on project requirements and anticipated seasonal weather conditions for the project schedule. Design to include evaluation of existing conditions, humidity, and temperature, proper air exchange requirements, ventilation requirements, ducting requirements for adequate air flow, and any other issues necessary to achieve the specified performance and environmental conditions throughout the duration of the project.
D. CONTRACTOR to submit written recommendations from dehumidification subcontractor for bulkhead locations, bulkhead venting, duct work for each bulkhead section, any secondary ventilation requirements for coating cure, dust collection equipment CFM requirements, and drying requirements for blast hose compressed air necessary to maintain environmental control as specified herein.
E. Dehumidification subcontractor shall either operate the equipment or provide training to CONTRACTOR on the proper operation and setup of dehumidification equipment. Dehumidification subcontractor shall provide a technical representative on site for a minimum of two 8 hour days to insure proper operation of the equipment, achievement of desired environmental control, and to insure CONTRACTOR can properly setup, operate, monitor, and maintain the equipment.
F. Dehumidification shall be operated in a manner that prevents all condensation or icing throughout surface preparation and coating application and cure.
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G. Reblasting of flash rusted metal surfaces or removal of damaged coatings, as a result of equipment malfunction, shutdown, or other events that result in the loss of environmental control, will be at the sole expense of the CONTRACTOR. Cleaned metal surfaces subject to flash rusting shall be cleaned to the same cleanliness as prior to the flash rust formation and shall be approved by the ENGINEER.
H. CONTRACTOR shall monitor ambient temperature, humidity, dew point temperature, and pipe surface temperature both outdoors and within the work area at the start, midpoint, and end of each work shift, minimum, but not greater than 5 hours between measurements.
I. Daily environmental condition monitoring and maintenance of the equipment shall be documented in writing and posted near the equipment for review by the ENGINEER.
3.05 VENTILATION AND ILLUMINATION
A. Adequate illumination shall be provided while work is in progress. Whenever required by the inspector, the CONTRACTOR shall provide additional illumination and necessary supports to cover all areas to be inspected. The level of illumination for inspection purposes shall be determined by the inspector.
B. Ventilation shall be used to control potential dust and hazardous conditions within the tank. Ventilation flow rates shall be in accordance with OSHA regulations and as required to reduce air contamination to nonhazardous conditions.
3.06 SURFACES NOT REQUIRING PAINTING
A. Unless otherwise stated herein or shown, the following areas or items will not require painting: 1. Concrete and masonry surfaces 2. Nonferrous and corrosion-resistant ferrous alloys such as copper, bronze, monel, aluminum, chromium plate, atmospherically exposed weathering steel, and stainless steel, except where: a. Required for electrical insulation between dissimilar metals. b. Aluminum and stainless steel are embedded in concrete or masonry, or aluminum is in contact with concrete or masonry. c. Color coding of equipment and piping is required. 3. Nonmetallic materials such as glass, PVC, wood, porcelain, and plastic (FRP) except as required for architectural painting or color coding. 4. Prefinished electrical and architectural items such as motor control centers, switchboards, switchgear, panel boards, transformers, disconnect switches, acoustical tile, cabinets, elevators, building louvers, wall panels, etc.; color coding of equipment is required. 5. Nonsubmerged electrical conduits attached to unpainted concrete surfaces. 6. Cathodic protection anodes. 7. Items specified to be galvanized after fabrication unless specifically required elsewhere or subject to immersion. 8. Insulated piping and/or insulated piping with jacket will not require exterior coating, except as required for architectural painting or color coding.
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3.07 PREPARATION OF SURFACES
A. Surface Preparation Inspection:
1. Inspect and provide substrate surfaces prepared in accordance with these Specifications and the printed directions and recommendations of paint manufacturer whose product is to be applied. 2. Provide Engineer minimum 3 days' advance notice prior to start of surface preparation work or coating application work. 3. Perform such work only in the presence of Engineer, unless Engineer grants prior approval to perform such work in Engineer's absence.
B. Metal Surface Preparation: 1. General: a. Do not perform a surface preparation blast prior to submission of samples. Workmanship for metal surface preparation as specified shall meet current Steel Structures Painting Council (SSPC) Specifications as follows: (1) Solvent Cleaning: SP 1 (2) Hand Tool Cleaning: SP 2 (3) Power Tool Cleaning: SP 3 (4) White Metal Blast Cleaning: SP 5 (5) Commercial Blast Cleaning: SP 6 (6) Brush-Off Blast Cleaning: SP 7 (7) Pickling: SP 8 (8) Near-White Blast Cleaning: SP 10 (9) Bare Metal Power Tool Cleaning: SP 11 b. All surface preparation shall be assumed to be on a SSPC Grade A steel surface condition, unless specifically noted otherwise. c. Wherever the words "solvent cleaning", "hand tool cleaning", "wire brushing", or "blast cleaning", or similar words of equal intent are used in these Specifications or in paint manufacturer's specifications, they shall be understood to refer to the applicable SSPC Specifications listed above. d. Where OSHA or EPA regulations preclude standard abrasive blast cleaning, wet or vacu-blast methods may be required. Coating manufacturers' recommendations for wet blast additives and first coat application shall apply. Wet blasting methods shall be approved by the Engineer. e. Hand tool clean areas that cannot be cleaned by power tool cleaning. 2. Welds and adjacent areas: a. Prepared such that there is: (1) No undercutting or reverse ridges on the weld bead. (2) No weld spatter on or adjacent to the weld or any other area to be painted. (3) No sharp peaks or ridges along the weld bead. b. Grind embedded pieces of electrode or wire flush with the adjacent surface of the weld bead. 3. Preblast Cleaning Requirements: a. Remove oil, grease, welding fluxes, and other surface contaminants prior to blast cleaning. b. Cleaning methods: Steam, open flame, hot water, or cold water with appropriate detergent additives followed with clean water rinsing.
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c. Clean small isolated areas as above or solvent cleaned with suitable solvents and clean cloths. d. Round or chamfered all sharp edges and grind smooth burrs, jagged edges, and surface defects. 4. Blast Cleaning Requirements: a. General: (1) Type of Equipment and Speed of Travel: Designed to obtain specified degree of cleanliness. (2) Select type and size of abrasive to produce a surface profile that meets the coating manufacturer's recommendations for the particular coating to be applied or not less than 20 percent of the specified coating thickness, whichever is more stringent. (3) Meet applicable federal, state, and local air pollution control regulations for blast cleaning and disposition of spent aggregate and debris. (4) Do not reuse abrasive, unless abrasive is recyclable steel grit or shot abrasive. b. Shop Blasting (1) Notify Engineer at least 7 days prior to start of shop blast cleaning to allow for inspection of the work during surface preparation and shop application of paints. Work shall be subject to the Engineer's approval before shipment to the jobsite. (2) Items such as structural steel, metal doors and frames, metal louvers, and similar items as reviewed by the Engineer may be shop prepared and primed. Centrifugal wheel blast cleaning is an acceptable alternate to shop blast cleaning. Blast clean and prime in accordance with these Specifications. c. Field Blasting (1) Perform sandblasting for items and equipment where specified and as required to restore damaged surfaces previously shop or field blasted and primed. Materials, equipment, procedures, shall meet requirements of Steel Structures Painting Council. (2) Field blasting in areas with electrical or mechanical equipment, within buildings, or on coated surfaces with lead paint greater than 2,000 mg/L total lead shall be performed with dustless abrasive systems such as “Sponge-Jet”, dry ice abrasive blasting. 5. Post-Blast Cleaning and Other Cleaning Requirements: a. Clean surfaces of dust and residual particles from cleaning operations by dry (no oil or water vapor) air blast cleaning or other method prior to painting. Vacuum clean enclosed areas and other areas where dust settling is a problem and wiped with a tack cloth. b. Paint surfaces the same day they are sandblasted. Reblast surfaces that have started to rust before they are painted.
C. Concrete Surface Preparation: 1. Do not begin until 30 days after the concrete has been placed. 2. Remove grease, oil, dirt, salts or other chemicals, loose materials or other foreign matter by solvent, detergent, or other suitable cleaning methods. 3. Clean concrete using mechanical or chemical methods for the degree of cleaning specified for the coating system in accordance with SSPC SP-13, Surface preparation of Concrete. 4. Unless otherwise required for proper adhesion, ensure surfaces are dry prior to coating.
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5. Bug holes, air pockets, and other voids in the concrete will be filled or patched in chemical exposure areas, secondary containment, and where specifically required. 6. Concrete Surface Preparation Inspection: a. Adhesion Testing: (1) Tensile testing of the surface preparation shall be performed by the Engineer as necessary using Type 4 or Type 5 pneumatic adhesion testing equipment in accordance with ASTM D4541 using 2-inch diameter dollies for concrete surface adhesion testing. (2) Applied coating greater than 20 mils in thickness or with a tensile strength greater than 2,500 psi shall be scored for concrete adhesion testing. (3) Adhesive failure greater than 50 percent of the dolly surface area shall indicate inadequate surface preparation. (4) Cohesive failures which results in loss of sound concrete will be acceptable provided the loss is greater than 50 percent of the dolly surface area. (5) Low adhesion cohesive failures with a thin layer of concrete due to weak concrete or laitance over 50 percent of the dolly surface will be rejected. b. Concrete Soundness: (1) Concrete soundness shall be determined using the scratching or hammer impact methods as defined in SSPC SP-13. c. Moisture Content: (1) Moisture shall be tested as Specified in SSPC SP-13 and shall not exceed the moisture content recommended by the coating manufacturer.
D. Plastic Surface Preparation: 1. Hand sand plastic surfaces to be coated with a medium grit sandpaper to provide tooth for the coating system. 2. Large areas may be power sanded or brush-off blasted, provided sufficient controls are employed so the surface is roughened without removing excess material.
E. Brush-off Blast Cleaning: 1. Equipment, procedure, and degree of cleaning shall meet SSPC-SP 7, Brush- off Blast Cleaning and shall achieve a profile on the coating equivalent to 80 grit sandpaper with no exposed metal. 2. Where metal substrate is exposed, Contractor shall apply full coating system as specified for new metal surfaces. 3. Repair or replace surfaces damaged by blast cleaning, where damage is defined as visible metal substrate. If less than 5 percent of prepared surface has the metal substrate visible, the coating shall be repaired by application of a brush applied intermediate coat. If greater than 5 percent the coating shall be fully removed to meet the specified surface cleanliness and recoated with the specified coating system. 4. Abrasive: Either conventional abrasive blasting with sand, grit, or nut shells or specialized abrasive blasting. Abrasives shall be 60 mesh grit, maximum. 5. Select various surface preparation parameters such as size and hardness of the abrasive, nozzle size, air pressure, and nozzle distance from the surface such that the surface is cleaned without pitting, chipping, or other damage.
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6. Verify parameter selection by blast cleaning a trial area that will not be exposed to view. 7. The Engineer shall approve trial blast cleaned area and shall used area as a representative sample of surface preparation.
F. Solvent Cleaning: 1. Consists of removal of foreign matter such as oil, grease, soil, drawing and cutting compounds, and any other surface contaminants by the use of solvents, emulsions, cleaning compounds, steam cleaning, or similar materials and methods which involve a solvent or cleaning action. 2. Method meets SSPC-SP 1.
3.08 PROTECTION OF MATERIALS NOT TO BE PAINTED
A. Remove, mask, or otherwise protect hardware, lighting fixtures, switch plates, aluminum surfaces, machined surfaces, couplings, shafts, bearings, nameplates on machinery, and other surfaces not intended to be painted.
B. Provide drop cloths to prevent paint materials from falling on or marring adjacent surfaces.
C. Protect working parts of mechanical and electrical equipment from damage during surface preparation and painting process.
D. Mask openings in motors to prevent paint and other materials from entering the motors.
3.09 PAINT MIXING
A. Multiple-component coatings: 1. Prepare using all of the contents of the container for each component as packaged by the paint manufacturer. 2. No partial batches will be permitted. 3. Do not use multiple-component coatings that have been mixed shall not be used beyond their pot life. 4. Provide small quantity kits for touchup painting and for painting other small areas. 5. Mix only components specified and furnished by the paint manufacturer. 6. Do not intermix additional components for reasons of color or otherwise, even within the same generic type of coating. 7. Fast set or plural component products shall be applied using an appropriate multipart pump that properly mixes both components at the recommended ratio using equipment recommended by the coating manufacturer. Hot mixing of fast set or plural component products will not be permitted.
B. Keep paint materials sealed when not in use and provide nitrogen blanket on fast set, plural, or moisture cured coatings on opened product containers when stored or not in use more than 8 hours.
C. Where more than one coat of a material is applied within a given system, alternate color to provide a visual reference that the required number of coats have been applied.
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3.10 APPLICATION OF PAINT
A. General: 1. Inspection: Schedule with Engineer in advance for cleaned surfaces and all coats prior to the succeeding coat. 2. Apply coatings in accordance with the paint manufacturer's recommendations. Allow sufficient time between coats to assure thorough drying of previously applied paint. 3. Fusion Bonded Coatings Method Application: Electrostatic, fluidized bed, or flocking. 4. Paint units to be bolted together and to structures prior to assembly or installation. 5. Shop Primed or Factory Finished Surfaces: a. Inspection: Schedule with Engineer in advance for shop primed or factory- finished items delivered to jobsite for compliance with these Specifications. b. Hand or power sand areas of chipped, peeled, or abraded coating, feathering the edges. Follow with a spot primer using specified primer. c. For two-package or converted coatings, consult the coatings manufacturer for specific procedures as relates to top coating of these products. d. Prior to application of finish coats, clean shop primed surfaces of dirt, oil, and grease, and apply a mist coat of specified primer, 1.0 mil dry film thickness. e. After welding, prepare and prime holdback areas as required for the specified paint system. Apply primer in accordance with manufacturer's instructions. 6. Manufacturer Applied Paint Systems: a. Repair abraded areas on factory-finished items in accordance with the equipment manufacturer's directions. b. Carefully blend repaired areas into the original finish.
B. Application Safety 1. Performed painting in accordance with recommendations of the following: a. Paint manufacturer's instructions. b. NACE contained in the publication, Manual for Painter Safety. c. Federal, state, and local agencies having jurisdiction. 2. CONTRACTOR will be solely and completely responsible for condition of the project site, including safety of all persons (including employees) and property during performance of the work. This requirement will apply continuously and not be limited to normal working hours. Safety provisions will conform to U.S. Department of Labor, Occupational Safety and Health Act, any equivalent state law, and all other applicable federal, state, county, and local laws, ordinances, and codes. 3. CONTRACTOR will comply with all safety-training requirements promulgated or required for this project.
C. Film Thickness: 1. Coverage is listed as either total minimum dry film thickness in mils (MDFT) or the spreading rate in square feet per gallon (SFPG). Per coat determinations are listed as MDFTPC or SFPGPC. 2. Applied coating system film thickness per coat shall be applied at the specified coating thickness or the manufacturer’s recommended minimum thickness,
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whichever is greater. Where the manufacturer has not specified a minimum coating thickness on the product data sheets, the minimum recommended coating application thickness shall apply. 3. Maximum film build per coat shall not exceed the coating manufacturer's recommendations. 4. D. Stripe Coats: 1. Surfaces that are subject to immersion, condensing environments, or where specifically specified shall be stripe coated on all angles, edges, corners, threads, welds, and similar type surfaces. 2. Stripe coat shall be an extra coat of the intermediate coating material and shall be applied between the prime and intermediate coats. 3. The stripe coat shall be a separate coat from coats specified under the coating system. 4. Stripe coats shall be alternated in color similar to a full coat. E. Number of coats: 1. Apply specified number of coats, minimum, irrespective of the coating thickness. 2. Additional coats may be required to obtain the minimum required paint thickness, depending on method of application, differences in manufacturers' products, and atmospheric conditions.
F. Porous Surfaces, Such as Concrete, Masonry: 1. Prime Coat: a. May be thinned to provide maximum penetration and adhesion. b. Type and Amount of Thinning: Determined by the paint manufacturer and is dependent on surface density and type of coating. c. Surfaces Specified to Receive Water Base Coating: Damp, but free of running water, just prior to application of the coating.
G. Existing Coated Surfaces: 1. General: a. Shop primed or coated surfaces shall be reviewed with the Engineer to determine the extent of coating damage and suitability of the finish coats to adhere to the shop applied coats. b. If a cured epoxy, polyurethane, or plural-component material is to be top coated, contact the coating manufacturer concerned for additional surface preparation requirements. At a minimum, existing coated surfaces shall be sanded to remove all gloss and roughen the existing surface for adhesion of subsequent coats. c. Profile on plural component or two component coatings shall be as specified for by the manufacturer or equivalent of 80 grit sandpaper; whichever is more stringent. d. Surface preparation recommendations of the manufacturer shall be subject to approval of the Engineer. e. All existing coated surfaces, where demolition of equipment was specified or required, shall be surface prepared, touch-up coating repairs completed, and a cosmetic overcoat applied using the specified coating system on all existing coated surfaces associated with the demolition work, unless otherwise specified.
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f. Existing coatings on immersed equipment shall be removed to bare metal and recoated with the specified coating system where demolition work was specified. g. Apply sealer/primer where recommended by coating manufacturer for coating compatibility. 2. To be Recoated or Final Coated: a. Detergent wash and freshwater rinse. b. Perform touch-up repairs of existing coating. c. Asphaltic varnish coated ductile iron pipe will require an application of a seal coat prior to the application of a cosmetic finish coat. 3. Touch-up Repairs: a. Clean loose, abraded, or damaged coatings to substrate by Power Tool (SP 3). b. Feather surrounding intact coating. c. Apply one spot coat of the specified primer to bare areas overlapping the prepared existing coating. d. Apply one full finish coat of the specified primer or finish coat(s) overall. 4. Application of a Cosmetic Coat: a. The exact nature of shop-applied coatings is not known in all cases. b. Check compatibility by application to a small area prior to starting the coating. c. If lifting or other problems occur, request disposition from the Engineer. d. Cured epoxy, polyurethane, plural component materials or any other coating system that has exceeded its maximum recoat window shall be prepared as specified this section.
H. Damaged Coatings, Pinholes, and Holidays: 1. Feather edges and repaired in accordance with the recommendations of the paint manufacturer. 2. Repair fusion bonded coatings to be as recommended by the original applicator. Applicator shall provide liquid repair kits for this purpose as recommended by the coating manufacturer. 3. Apply finish coats, including touchup and damage-repair coats in a manner that will present a uniform texture and color-matched appearance.
I. Unsatisfactory Application: 1. If the item has an improper finish color, or insufficient film thickness, clean and topcoat surface with specified paint material to obtain the specified color and coverage. Obtain specific surface preparation information from the coating manufacturer. 2. Hand or power sand visible areas of chipped, peeled, or abraded paint and feather the edges. Follow with primer and finish coat in accordance with the Specifications. Depending on the extent of repair and its appearance, a finish sanding and topcoat may be required. 3. Evidence of runs, bridges, shiners, laps, or other imperfections shall be cause for rejection. 4. Repair defects in coating system per written recommendations of coating manufacturer. 5. Leave all staging up until the Engineer has inspected the surface or coating. Replace staging removed prior to approval by Engineer.
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3.11 COATING INSPECTION
A. General 1. Film thickness measurements and electrical inspection of the coated surfaces: 2. Perform with properly calibrated instruments. 3. Recoat and repair as necessary for compliance with the Specifications. 4. All coats will be subject to inspection by the Engineer and the coating manufacturer's representative. 5. Visually inspect concrete, nonferrous metal, plastic, and wood surfaces to ensure proper and complete coverage has been attained. 6. Give particular attention to edges, angles, flanges, and other areas where insufficient film thicknesses are likely to be present and ensure proper milage in these areas.
B. Coating Thickness Testing: 1. ENGINEER shall conducted coating thickness testing as necessary and without limitation. Testing conformance to the requirements of SSPC PA-2 is specifically excluded from this specification. 2. Measure coating thickness specified in mils with a magnetic type dry film thickness gauge as specified. 3. Check each coat for the correct milage. Do not make measurement before a minimum of 8 hours after application of the coating. 4. Tests for concrete coating thickness shall be with a Tooke Gauge, a destructive test. Contractor shall repair coating after thickness testing.
C. Coating Continuity Testing 1. Holiday detect coatings with high voltage units in accordance with NACE RP0188. High voltage detector shall have adjustable voltages in 100 volt increments and shall be operated in accordance with the manufacturer’s instructions and the specified standard. 2. Use of an electrical holiday detector, low voltage, wet sponge type holiday detector will be permitted for coating systems less than 20 mils total dry film thickness and are not for immersion or condensing environments. 3. Holiday detect coatings on pipe for buried application with high voltage spark tester in accordance with NACE RP0274.
3.12 CLEANUP
A. Place cloths and waste that might constitute a fire hazard in closed metal containers or destroyed at the end of each day.
B. Upon completion of the work, remove staging, scaffolding, and containers from the site or destroyed in a legal manner.
C. Completely remove paint spots, oil, or stains upon adjacent surfaces and floors and leave entire job clean.
D. Damages due to over spray on buildings, vehicles, trees, or other surfaces not specified to be painted would be the responsibility of the CONTRACTOR.
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3.13 MANUFACTURER' SERVICES
A. Furnish paint manufacturer's representative to visit jobsite at intervals during surface preparation and painting as may be required for product application quality assurance, and to determine compliance with manufacturer's instructions and these specifications, and as may be necessary to resolve field problems attributable to, or associated with, manufacturer's products furnished under this Contract.
3.14 PROTECTIVE COATING SYSTEMS AND APPLICATION SCHEDULE:
A. Unless otherwise shown or specified in these Specifications painted or coated the work in accordance with the following application schedule.
B. In the event of discrepancies or omissions in the following, request clarification from the Engineer before starting the work in question.
System No. Title 1 SUBMERGED METAL - POTABLE WATER 4 EXPOSED METAL - HIGHLY CORROSIVE 5 EXPOSED METAL - MILDLY CORROSIVE 8 BURIED METAL - GENERAL 10 GALVANIZED METAL CONDITIONING 11 GALVANIZED METAL REPAIR 21 EPOXY FLOOR, CONCRETE 22 SECONDARY CONTAINMENT, CONCRETE 27 ALUMINUM AND DISSIMILAR METAL INSULATION 29 FUSION BONDED COATING
C. System No. 1 Submerged Metal - Potable Water:
1. Surface Preparation and Coating System
Surface Prep. Paint Material Min. Coats, Cover Abrasive Blast, or Potable Grade, 3 coats, 3 MDFTPC Centrifugal Wheel Polyamide Epoxy Blast (SP 5) Coating
2. Application: a. All metal surfaces, new and existing, below a plane 1 foot above the maximum liquid surface, metal surfaces above the maximum liquid surface which are a part of the immersed equipment, concrete embedded surfaces of metallic items under submerged conditions, such as wall pipes, pipes, pipe sleeves, access manholes, gate guides and thimbles, and structural steel, except reinforcing steel, unless otherwise specified:
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b. Use on the following areas: (1) Buried miscellaneous metallic components that cannot be coated per Section 09910 as approved by the Engineer. c. Use on the following surfaces: (1) Lining for valve bypass piping and blowoff piping 10-inches diameter or less. (2) Interior of access manways
3. Special Requirements: (1) All existing immersed metal surfaces with an existing coating system, excluding new shop primed or coated equipment, shall be abrasively blasted to bare metal and recoated with this system.
D. System No. 4 Exposed Metal - Highly Corrosive:
1. Surface Preparation and Coating System
Surface Prep. Paint Material Min. Coats, Cover Abrasive Blast, or Organic Zinc Rich Primer 1 coat, 2.5 MDFT Centrifugal Wheel Blast Polyamide Epoxy 1 coat, 5 MDFT (SP 10) Polysiloxane 2 coats, 6 MDFT
2. Application: a. Exposed metal surfaces, new and existing, located inside of structures, manholes, vaults, and the following specific areas unless otherwise specified. b. Use on the following items or surfaces: (1) Exterior surfaces of metallic piping, valves, couplings, pipe supports, and all other exposed metal components within the following areas, unless otherwise specified: (a) Bluffdale meter vault (b) 150th South Interconnection vault (c) Mainline Valve and Blowoff vault (d) Fluoride building meter vault 3. Special Requirements: a. The surface preparation and primer shall be shop applied to all surfaces prior to installation. b. Galvanized steel surfaces shall be coated per the coating manufacturer’s requirements. c. Insulated piping shall be primed and epoxy coated prior to installation of insulation. d. All existing exposed metal surfaces with an existing coating system, including new shop primed or coated equipment, shall be prepared as specified under “Coating Application, Existing Coated Surfaces” and final topcoat applied per this system. e. Aliphatic polyurethane will not be allowed as a substitute for polysiloxane due to restrictive overcoat requirements. f. Dry film coating thickness of polysiloxane, including touch up repairs, shall not exceed the manufacturer’s recommended maximum film thickness.
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E. System No. 5 Exposed Metal - Mildly Corrosive:
1. Surface Preparation and Coating System
Surface Prep. Paint Material Min. Coats, Cover Abrasive Blast, or Inorganic Zinc Rich Primer 1 coat, 2.5 MDFT Centrifugal Wheel Blast Polysiloxane 2 coats, 6 MDFT (SP 10)
2. Application: a. Exposed metal surfaces, new and existing, located outside of structures and exposed to weather and the following specific surfaces unless otherwise specified. b. Use on the following items or surfaces: (1) Exposed surfaces of blowoff piping, unless hot dipped galvanized (2) Exposed surfaces of air vent piping, unless hot dipped galvanized. (3) Hollow metal doors per architectural drawings. 3. Special Requirements: a. Surface preparation, primer, and one of two topcoats shall be shop applied to all surfaces prior to installation with final topcoat to be field applied for color uniformity after all touchup repairs have been completed. b. Galvanized steel surfaces shall be coated per the coating manufacturer’s requirements. c. Polysiloxane coating to overlap buried pipe coating a minimum of 4 inches below top of concrete. d. Aliphatic polyurethane will not be allowed as a substitute for polysiloxane due to restrictive overcoat requirements. e. Dry film coating thickness of polysiloxane, including touch up repairs, shall not exceed the manufacturer’s recommended maximum film thickness.
F. System No. 8 Buried Metal - General:
1. Surface Preparation and Coating System
Surface Prep. Paint Material Min. Coats, Cover Abrasive Blast or Wax Tape Coating Wax tape as specified in Centrifugal Wheel Blast Section 09910 (SP 10)
2. Application: a. All buried pipe shall be coated as specified under Section 09910, Pipeline Coatings. b. All buried, below grade portions of steel items, except buried stainless steel or ductile iron, and the following specific surfaces unless otherwise specified. 3. Special Requirements: a. Metallic air vent pipe, buried, may be coated with System No. 1 at Contractor’s option.
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G. System No. 10 Galvanized Metal Conditioning:
1. Surface Preparation and Coating System
Surface Prep. Paint Material Min. Coats, Cover Solvent Clean (SP 1) Wash Primer 1 Coat, 0.4 MDFT Followed by Hand Tool (SP Finish Coats to Match As Required to Match 2) or Power Tool (SP 3) Existing Paint Surrounding Area
2. Application: a. All galvanized surfaces requiring painting and the following specific surfaces unless otherwise specified.
3. Special Requirements: a. Sweep blast as specified this section, may be used in lieu of hand or power tool cleaning of galvanized surfaces provided CONTRACTOR can demonstrate that damage to the zinc coating will not result. ENGINEER approval of sweep blasting locations, methods, and surface cleanliness and profile results is required. b. See applicable coating systems for finish coating system and coating requirements based on area and/or surface to be coated.
H. System No. 11 Galvanized Metal Repair:
1. Surface Preparation and Coating System
Surface Prep. Paint Material Min. Coats, Cover Solvent Clean (SP 1) Organic Zinc Rich Primer or 1 Coat, 3 MDFT Followed by Hand Tool (SP Inorganic Zinc Rich Primer 2), or Power Tool (SP 3), or Brush-off Blast (SP 7)
2. Application: a. All galvanized surfaces which are abraded, chipped, or otherwise damaged and the following specific surfaces unless otherwise specified. .
I. System No. 21 Epoxy Floor, Concrete:
1. Surface Preparation and Coating System
Surface Prep. Paint Materials Min. Coats, Cover Concrete Polyamide Epoxy 1st coat (thinned) 2 coats Total system 80 SFPG
2. Application: a. Use on the following areas: (1) The floors of all cast-in-place concrete vaults.
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(2) All other areas as shown on the Drawings or specified to receive, epoxy floor coating, concrete. (3) Concrete floors of Fluoride building vault, except areas specified to be coated with System No. 22.
3. Special Requirements: a. Epoxy coating to be applied a minimum of 6-inches onto walls, pipe supports, and any other metallic component attached to the floor or wall within the 6-inch limit. b. All areas above the 6-inch limit shall be masked off, provide a straight line demarking coated versus uncoated areas. c. Abrasively blast miscellaneous metal surfaces to an SSPC SP-10, near white blast, as specified this section. d. Prime coat of epoxy shall be a thinned coat of the epoxy coating to fill and seal the concrete before the final coats applied, per the coating manufacturer’s requirements.
J. System No. 22 Secondary Containment, Concrete:
1. Surface Preparation and Coating System
Surface Prep. Paint Materials Min. Coats, Cover Concrete Surface Filler: Tnemec 215 Per manufacturers or equal recommendations.
Primer: Tnemec 120-5002 1 coat, 60 to 80 SFPGPC or equal
Finish Coats: Tnemec 120- 1 Coat, 60 to 80 SFPGPC 5001 or equal
2. Application: a. Use on the following areas: (1) Floor and pipe gallery of fluoride storage and handling area of the Fluoride Building.
3. Special Requirements: a. Coating system shall have a proven record of performance in secondary containment of hydrofluoric acid for 72 hours, minimum, with no damage. b. Contractor to verify moisture permeation of concrete walls and floor where coating is to be applied in accordance with ASTM F1869, "Standard Test Method for Measuring Moisture Vapor Emission Rate of Concrete Subfloor Using Anhydrous Calcium Chloride". c. Concrete surfaces to be filled per manufacturers recommendations. d. All joints or concrete cold joints are to be prepared and treated in accordance with the coating manufacturer’s recommendations. e. Coating to be applied a minimum of 6-inches onto walls, pipe supports, and any other metallic component attached to the floor or wall within the 6- inch limit. f. All areas above the 6-inch limit shall be masked to provide a straight line demarking coated versus uncoated areas.
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g. Abrasively blast miscellaneous metal surfaces to an SSPC SP-10, near white blast, as specified this section.
B. System No. 27 Aluminum and Dissimilar Metal Insulation:
1. Surface Preparation and Coating System
Surface Prep. Paint Material Min. Coats, Cover Solvent Clean (SP 1) Wash Primer 1 coat, 0.4 MDFT Polyamine Epoxy 1 coat, 8 MDFT
2. Application: a. Use on all non-submerged concrete embedded aluminum surfaces, and the following specific surfaces unless otherwise specified. b. Use on the following surfaces: (1) All concrete embedded components of vault hatches (2) All concrete embedded surfaces where electrical isolation from concrete reinforcement is required.
C. System No. 29 Fusion Bonded Coating:
1. Surface Preparation and Coating System
Surface Prep. Paint Material Min. Coats, Cover Abrasive Blast, or Fusion Bonded 100% solids 1 or 2 coats, 10 MDFT Centrifugal Wheel Blast Epoxy or Polyurethane (SP 10) or Acid Pickling (SP 8)
2. Application: a. Use where specified. b. Use on the following items or surfaces: (1) Concrete embedded anchor bolts, except threads. (2) Removable handrail sleeves.
3. Special Requirements: a. System 1 may be used as alternative coating system at Contractor’s option
1.02 ARCHITECTURAL PAINT SYSTEMS:
System No. Title 102 WOOD, SEMI-GLOSS (INTERIOR OR EXTERIOR) 109 CONCRETE MASONRY, SEMI-GLOSS 115 GYPSUM WALLBOARD AND PLASTER, SEMI-GLOSS
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A. System No. 102 Wood, Semi-Gloss (Interior or Exterior):
1. Surface Preparation and Coating System
Surface Prep. Paint Material Min. Coats, Cover Wood Alkyd Wood Primer 1 coat, 400 SFPG Alkyd (Semi-Gloss) 1 coat, 400 SFPG
2. Application: a. Use on the following areas: (1) Refer to architectural Drawings for Finish and Color Schedules. b. Use on the following items or surfaces: (1) Interior of Fluoride Building, per the architectural drawings.
B. System No. 109 Concrete Masonry, Semi-Gloss:
1. Surface Preparation and Coating System
Surface Prep. Paint Material Min. Coats, Cover Masonry Block Filler 1 coat, 75 SFPG Acrylic Sealer 2 coats, 100 SFPGPC
2. Application: a. Use on the following areas: (1) Refer to architectural Drawings for Finish and Color Schedules. b. Use on the following items or surfaces: (1) Interior of Fluoride Building, per architectural drawings.
C. System No. 115 Gypsum Wallboard and Plaster, Semi-Gloss:
1. Surface Preparation and Coating System
Surface Prep. Paint Material Min. Coats, Cover Remove all Oil, Grease, and Latex Primer/Sealer 1 coat, 350 SFPG Loose Particles Alkyd (Semi-Gloss) 2 coats, 400 SFPGPC
2. Application: a. Use on the following areas: (1) Refer to architectural Drawings for Finish and Color Schedules. b. Use on the following items or surfaces: (1) Interior of Fluoride Building, per architectural drawings.
(See PSDS form following this section)
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PAINT SYSTEM DATA SHEET
Attached products' Technical Data Sheet (if applicable) to this sheet for each paint system submittal.
Paint System Number (from spec.): Paint System Title (from spec.): Coatings Manufacturer: Representative: Surface Preparation:
Product Name/Number Paint Material (Generic) Proprietary) Min. Coats, Coverage
Additional Information Required (check applicable items):
ANSI/NSF Certification letter for each paint material listed above requiring ANSI/NSF Standard 60 and 61 approval.
Manufacturer’s minimum and maximum recommended coating thickness per coat and for total coating system.
Immersion coating cure requirements from minimum coating application temperature to 100 degrees in 15-degree temperature increments.
Central Pipeline Project PAINTING June 16, 2014 09900-25
SECTION 09910 PIPELINE COATING AND LINING
PART 1 GENERAL
1.01 WORK RESULTS
A. This section covers the work necessary to apply and external coating and internal lining on steel pipe, field coating of joints, and field repair of coating damage, complete.
B. Steel pipe will supplied from the fabricator with either a tape wrap or polyurethane coating system, and, where specifically required, the dielectric coating system shall be over coated with cement mortar.
C. Exposed steel pipe will be shop finish coated as specified in Section 09900, PAINTING, unless specifically specified otherwise.
D. See section GENERAL CONDITIONS, which contain information and requirements that apply to the work specified and are mandatory for this project.
E. Related sections: 1. The Contract Documents are complementary; what is called for by one is as binding as if called for by all. 2. It is the CONTRACTOR’s responsibility for scheduling and coordinating the Work of subcontractors, suppliers, and other individuals or entities performing or furnishing any of CONTRACTOR’s Work. 3. The following Sections are related to the Work described in this Section. This list of Related Sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the CONTRACTOR to see that the completed Work complies accurately with the Contract Documents. a. Section 01300 – Contractor Submittal. b. Section 09900 – Painting. c. Section 13115 – Impressed Current Cathodic Protection.
1.02 GENERAL
A. See section GENERAL CONDITIONS, which contain information and requirements that apply to the work specified and are mandatory for this project.
1.03 SUBMITTAL REQUIREMENTS
A. Contractor submittals shall be made in accordance with Section 01300 of these Specifications.
B. Shop Drawings: Catalog cuts and other information for all products proposed. Provide copy of approved coating system submittals to the coating applicator.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-1 C. Quality Control Submittals: Furnish the following:
1. Applicator's Experience with list of references substantiating compliance. 2. Coating manufacturer's certification stating the individual coating applicators have met the qualification certification requirements as specified this section. 3. Coating manufacturer shall provide a copy of the manufacturer’s coating application quality assurance manual. 4. If the manufacturer of field-applied coating differs from that of the shop applied primer, provide written confirmation from both manufacturers’ that the two coating materials are compatible.
1.04 QUALITY ASSURANCE
A. Coating Applicator's Experience and Certification:
1. Coating Application Company and coating application supervisor (Certified Applicator) shall have a minimum of 5 years experience applying the specified coating system. 2. Coating application personnel, whom have direct coating application responsibility, shall have a minimum of 2 years practical experience in application of the indicated coating system. 3. Coating applicator shall be certified by the coating manufacturer as an approved applicator.
B. Coating and/or lining manufacturer technical representative shall be present for a minimum of one day technical assistance and instruction at the start of coating and/or lining operations within the shop. During this visit, the technical representative shall observe surface preparation and coating application and conduct tests of the coating to insure conformance with application instructions, recommended methods, and conditions.
C. Coating and/or lining manufacturer’s technical representative shall be onsite for one working day, minimum, at the start of each construction season to inspect coating application and procedures in the field. During this visit, the technical representative shall observe surface preparation and coating application and conduct tests of the coating to insure conformance with application instructions, recommended methods, and conditions.
D. Coating and/or lining manufacturer shall include 8 hours per month of field or shop coating technical support when requested by the Engineer.
E. Technical representative shall provide a written report to the Engineer for each visit. Report shall include copies of test data collected, description of observations, and all recommended corrective actions. Report shall be submitted within 5 working days after the visit. When deemed necessary by the Engineer, work will not be permitted to proceed until the recommended corrective actions have been implemented. After all corrective recommendations have been completed; the manufacturer representative shall return and certify that the application complies with the manufacturer’s coating application recommendations.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-2 F. Additional visits by the manufacturer’s representative shall be made at sufficient intervals during surface preparation and coating or lining as may be required for product application quality assurance, and to determine compliance with manufacturer’s instructions, and as may be necessary to resolve problems attributable to, or associated with, manufacturer’s products furnished for this project.
1.05 ABBREVIATIONS
MDFT Minimum Dry Film Thickness mil Thousandths of an Inch
1.06 DEFINITIONS
A. Manufacturer's Representative: Employee of coating manufacturer who is factory trained and knowledgeable in all technical aspects of their products and systems. Sales representatives are not acceptable as a technical representative unless written authorization from the coating manufacture is provided which states the sales representative has full authority to act on the behalf of the coating manufacturer.
1.07 REFERENCE STANDARDS A. This specification recognizes AWWA, NACE, and SSPC standards as minimum industry standards and they are referenced for purpose of conformance, except where modified in this section. The requirements of this specification section have been written to a higher design standard with the intent of achieving a long term coating performance of 100 years.
AWWA C205 Cement-Mortar Protective Lining and Coating for Steel Water Pipe-4- inch and Larger- Shop Applied. AWWA C210 Liquid-Epoxy Coating Systems for the Interior and Exterior of Steel Water Pipelines. AWWA C214 Tape Coating Systems for the Exterior of Steel Water Pipelines. AWWA C216 Heat-shrinkable Cross-linked Polyolefin Coatings for the Exterior of Special Sections, Connections, and Fittings for Steel Water Pipelines. AWWA C217 Cold-Applied Petrolatum Tape and Petroleum Wax Tape Coatings for the Exterior of Special Sections, Connections, and Fittings for Steel Water Pipelines. AWWA C222 Polyurethane Coatings for Interior and Exterior of Steel Water Pipe and Fittings NACE RP-0274 High Voltage Electrical Inspection of Pipeline Coatings Prior to Installation.
SSPC-SP-1 Solvent Cleaning Surface Preparation SSPC-SP-2 Hand Tool Cleaning Surface Preparation SSPC-SP-3 Power Tool Cleaning Surface Preparation SSPC-SP-5 White metal Abrasive Blast Surface Preparation SSPC-SP-6 Commercial Abrasive Blast Surface Preparation SSPC-SP-10 Near White Metal Abrasive Blast Surface Preparation SSPC-SP-11 Power Tool Cleaning to Bare Metal
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-3
1.08 SPECIAL WARRANTY REQUIREMENTS
A. The Contractor and coating applicator shall warrant to the Owner and guarantee the work under this section against defective workmanship and materials for a period of two (2) years commencing on the date of final acceptance of the work.
1.09 OBSERVATION OF WORK
A. The Contractor shall give the Owner Representative a minimum of 14 days advance notice of the start of any work to allow scheduling for shop or field observation.
B. Provide Owner Representative a minimum 3 days' notice for actual start of surface preparation and coating application work.
C. Provisions shall be made to allow Owner’s representative full access to facilities and appropriate documentation regarding coating application.
D. Observation by the Owner’s representative or the waiver of observation of any particular portion of the work shall not be construed to relieve the Contractor of his responsibility to perform the work in accordance with these Specifications.
E. Materials shall be subject to testing for conformance with this specification as the Owner’s representative may elect, prior to or during incorporation into the work.
PART 2 MATERIALS
2.01 GENERAL
A. Coatings and linings will be stored and handled per manufacturer’s written directions.
B. Exterior and interior pipe and fitting surfaces shall be prepared and coated in accordance with referenced standards, written instructions of the coating or lining manufacturer, and these specifications, whichever is more stringent.
C. Pipeline coating or lining shall be the product of a single manufacturer. Product substitutions during the project will not be permitted, without ENGINEER approval.
2.02 SHOP-APPLIED EXTERIOR COATINGS
A. General
1. Steel and ductile iron pipe shall be coated in accordance with AWWA C214 or C222, except as modified herein, at the Contractors option.
2. Mortar over coat of dielectric coating shall be provided over Tape Wrap coating system (C214) and where specified or indicated on the Drawings. Steel pipe to receive a cement mortar overcoat shall be shop-coated with the required coating system and a 3/4-inch thick, minimum, cement mortar overcoat as specified herein.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-4
3. Pipe that is atmospherically exposed shall be shop coated as specified herein and Section 09900 PAINTING.
4. Buried dielectrically coated pipe and fittings passing through a concrete structure wall or floor shall be coated for a minimum of two-inches beyond the interior wall or floor surface.
B. Polyethylene Tape Wrap:
1. Pipe shall be coated with an 80 mil (nominal), tape-coating systems applied in accordance with AWWA C214, except as modified herein. a. Primer: Polyken 1019, 1027, 1029, or as recommended by the coating manufacturer. b. Weld Stripe Tape: Polyken 931 (no backing), 25 mils nominal, 4-inches wide minimum. c. Inner Wrap: Polyken 989 YGIII, 20 mils nominal, corrosion protection layer. d. Middle Wrap: Polyken 955 YGIII, 30-mils nominal, mechanical protection layer. Middle wrap may be eliminated when a cement mortar overcoat is required. e. Outer Wrap: Polyken 956 YGIII, 30 mils nominal, mechanical protection layer. f. Surface Preparation: (1) Steel Pipe: SSPC-SP5, White Metal blast, 2.5 mils blast profile, minimum. 2. Tape Coating: a. Tape layers shall have adhesive for the full width of the tape. Adhesive shall have the ability to stick to itself and to the proceeding tape layer or pipe. b. Each layer shall be a different color or shade with the outer layer white. c. Outer wrap shall have sufficient ultraviolet (UV) inhibitors to resist above grade exposure for a minimum of 12 months or the proposed storage and construction time, whichever is greater. d. Tape width shall be 12-inches maximum. Wider tape will be conditionally allowed if the coating applicator can demonstrate that proper tensioning can be maintained and mechanical wrinkling prevented throughout the coating application. If at any time during the pipe fabrication tape quality becomes inconsistent with a wider tape, the Engineer can require the remainder of the pipe to be coated using the maximum specified tape width. e. Tape coated steel pipe shall be provided with a cement mortar overcoat as specified this section.
C. Plural Component Epoxy: 1. General: a. Plural component, epoxy coating system shall be applied as specified herein with the exception that AWWA C210 is incorporated by reference for product qualification and application requirements only. b. Where there is a conflict between C210 and this specification, the more stringent requirement shall apply. 2. Shop Surface Preparation: a. Steel pipe: SSPC-SP5, White Metal blast, 3.00 mil profile, minimum, or as required by the manufacturer, whichever is greater.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-5 3. Shop Applied Coating Requirements: a. Thickness: One coat, 35 mils total dry film thickness, minimum, or as required to meet limits specified for holiday and coating defects, this section. b. Epoxy: Self-priming, plural component, 100 percent solids, non-extended epoxy, suitable for burial or immersion, and meeting the requirements of AWWA C210 and the following, whichever is more stringent: 1) Resistance to Water Immersion (ASTM D870) or Wet Adhesion a) Acceptance criteria: (1) Not greater than 10 percent loss of substrate adhesion when compared to substrate adhesion in an unexposed area of the same sample with adhesion tests completed within 12 to 24 hours after test termination. Average of three pulls per exposure area. (2) No blistering or underfilm corrosion when viewed at 10x magnification. b) Adhesion Testing: (1) Method: ASTM D4541, Method E (2) Equipment: Type V, Delfesko Automatic AT Positest (3) Dollies: 20 mm and 14 mm, scored to metal substrate (4) Test Speed: 100 psi per second (both 14 and 20 mm) c) Test Duration:30 and 60 days 2) Cathodic Disbondment (ASTM G95) a) Acceptance criteria: 8 mm, maximum b) Potential: -3.00 volts c) Test Duration: 28 days d) Evaluation: Measured from original holiday radius to edge of staining on metal surface. 3) Water Absorption (ASTM D570) a) Acceptance Criteria: 1.80 percent, maximum b) Test Duration:30 day and 60 day 4) Long-Term Adhesion Test: (a) Acceptance Criteria: Not more than 10 percent loss of adhesion over duration of test. Differential based on the highest average adhesion result to the lowest average adhesion result. (b) Test Duration: 1 day, 7 days, 3 weeks, 2 months, and then monthly for total test duration of 12 months. (c) Sample Preparation: (1) SSPC-SP5, white metal abrasive blast, 3.00 mils profile, minimum. (2) Test area shall not exceed 18-inches by 18-inches. (3) Steel plate shall be a curved steel plate with a minimum radius of 15 inches to minimize standing water on the test panel. (4) Sample shall be exposed to ambient, outdoor conditions for the full duration of the test. (d) Test Procedure: (1) Long term adhesion shall be based on an 8 pulls per test period with the 3 lowest pulls discarded.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-6 (2) Test results per each test period shall be an average of the five highest pulls. (3) All adhesion pulls and their failure mode shall be recorded and those included in the average calculation shall be identified. (4) All adhesion tests shall be repaired to prevent water runoff from affecting subsequent adhesion tests. c. Shall be one of the following products: (1) Tnemec Series 431, Kansas City, MO (2) Or approved equal
D. Exterior Coating for Exposed Steel Pipe
1. All atmospherically exposed or vault piping shall be shop primed with the coating system as specified in Section 09900, PAINTING. 2. Exposed pipe to be shop primed per Section 09900 with intermediate and finish coats to be applied in the field after installation is complete. 3. Shop applied inorganic zinc primer shall not be applied at thickness greater than recommended by manufacturer. Excess primer to be removed using method recommended by coating manufacturer. 4. Manufacturer of shop-applied primer shall be coordinated with field application to provide a completed system by a single manufacturer. Engineer approval of a coating system with two or more coating manufacturer’s will require written approval from all coating manufacturer’s as to compatibility and acceptance under warranty.
E. Cement Mortar Overcoat
1. Cement mortar overcoat shall be applied over tape wrap coating system (C214) on steel pipe and fittings in accordance with AWWA C205, except as modified herein. 2. Holdback: a. Mortar overcoat shall be held back of dielectric coating a minimum of 3 inches for overlap of field applied joint coating onto dielectric coating system. 3. Shop Applied Coating System: a. Cement: Conform to ASTM C150, Type II. b. Aggregate shall be silica sand or other aggregate that is not subject to leaching. Conform to ASTM C33. c. Cement mortar mixture shall consist of 1 part cement to not more than 3 parts aggregate. d. Water for cement mortar: Clean and free from organic matter, strong alkalis, vegetable matter, and other impurities. Use no more than 4-1/2 gallons of water per sack of cement. e. Cement mortar coating: Nominal 1-inch thick coating with permitted tolerance of ±1/4-inch.
2.03 SHOP-APPLIED INTERIOR LININGS
A. Cement Mortar Lining:
1. Clean and cement mortar line steel pipe and fittings in accordance with AWWA C205. 2. Cement: Conform to ASTM C150, Type II.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-7 3. Shop applied cement mortar lining shall be uniform in thickness over the full length of the pipe joint. 4. Aggregate shall be silica sand or other aggregate that is not subject to leaching. Conform to ASTM C33. 5. Water for cement mortar: Clean and free from organic matter, strong alkalis, vegetable matter, and other impurities.
B. Liquid Applied Epoxy Coating:
1. Cement Mortar Lined Steel Pipe: a. Provide liquid epoxy primer and lining in all cement mortar lined metallic pipe at insulating joints for a minimum of two pipe diameters centered over the insulated joint. b. Epoxy lining shall be polyamine or polyamide cured, NSF approved for potable water contact in accordance with ANSI/NSF Standards 60 and 61, and capable of achieving full cure before placement in service or exposure to water. c. Application: (1) Apply in two coats at equivalent spread rate for 6 mils dry film thickness per coat with coating application efficiency of 80 percent.. (2) Epoxy shall be applied over the cement mortar lining where specified for the pipeline lining material. (3) Cement mortar shall be allowed to cure for a minimum of 15 days prior to surface preparation and coating application or 7 days with steam curing. Mortar lining shall be dry when epoxy lining is applied. (4) Prepare the cement mortar lining by abrasive blasting to remove all laitance and provide a surface profile equivalent to 80 grit sandpaper. 2. Steel Pipe Lining: a. Where epoxy lining is specified or shown on drawings, epoxy lining shall be applied directly to the steel surface. b. Surface Preparation: SP-5, White Metal Abrasive Blast c. Epoxy Lining: Polyamine or polyamide high build epoxy, NSF 60 and 61 approved, suitable for continuous immersion, and capable of achieving full cure before placement in service or exposing to water. d. Application: Apply in three coats at 5 mils minimum dry film thickness per coat with separate stripe coat at welds.
2.04 FIELD APPLIED COATINGS
A. General 1. All buried miscellaneous metal components installed on the pipeline and that is supplied bare or with a shop coating system that is not equal to the specified pipeline coating shall be coated in the field with one of the following coating systems. 2. Miscellaneous metal components shall include, but not be limited too, all exposed metals surfaces, including bolts, couplings, flanges, valves, adapters, pipe spools, and other miscellaneous metal components. 3. Coating system applied shall conform to the manufacturer’s requirements and shall be applied in accordance with the application requirements of the coating system.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-8 B. Petroleum or Wax Tape Coating: 1. Coating System: a. Surface Preparation: SP11 Power Tool to Bare Metal or SSPC-SP10, near white abrasive blast. b. Primer: petroleum or petrolatum wax c. Filler Material: (1) Filler materials shall be petroleum or petrolatum wax sealer/filler with closed cell plastic filler (2) Provide filler material to fill and smooth all irregular surfaces, such that no tenting or voids remain under the applied wax tape. d. Inner Tape: Petroleum or petrolatum wax impregnated fabric, 6-inch width maximum, 40 mils thick e. Outer Wrap: PVC or tape suitable for application to inner tape. f. Wax tape coating system shall be as manufactured by: (1) Denso North American (2) Trenton (3) Or approved equal. 2. Application: a. Coating shall be in accordance with AWWA C217, except as modified herein. b. Wax tape coatings shall be field applied on all buried couplings, thrust restraint rods and brackets, valves, and on joints, fittings, or irregular shapes or complex configurations that are not suited for the use of heat shrink coating systems and is not cement mortar over coated. c. Do not use wax tape coating systems on vault piping, atmospherically exposed piping and appurtenances, or where subject to UV exposures. d. Use sand backfill to protect wax coating from damage.
C. Epoxy Coating: 1. Coating System: a. Surface Preparation: SP11 Power Tool to Bare Metal or SSPC-SP10, near white abrasive blast. b. Primer: As required by the coating manufacturer. c. High Build Epoxy Coating: (1) Two component, high build polyamide or polyamine cured epoxy coating, suitable for direct burial or immersion, dries to touch in 2 or more hours, suitable for immersion or burial after full cure of coating. (2) Acceptable manufacturers: (a) ICI Devoe (b) Sherwin Williams (c) Carboline (d) Or approved equal d. Fast Cure Epoxy Coating: (1) Two component, 100% solids by volume, fast cure epoxy coating suitable for direct burial or immersion, dry to touch in less than 1 hour at 72 degrees, capable of curing while immersed or buried. (2) Acceptable Manufacturers: (a) TC 7010, Tapecoat Inc (b) Protal 7125, North American Denso
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-9 2. Application: a. Epoxy coatings on interior of pipe shall be NSF approved coatings suitable for potable water contact in accordance with ANSI/NSF Standards 60 and 61, unless otherwise approved by the Engineer. b. Contractor shall ensure that epoxy coating selected is suitable for the application temperatures anticipated and that project schedule will allow adequate cure time before backfill or immersion based on surface temperatures at the time of application. c. Epoxy coating shall be used for coating concrete embedded surfaces to a distance of 4 inches outside the interior and exterior surfaces of concrete wall or floors. Epoxy coating at concrete penetrations shall be a minimum of 12 mils dry film thickness.
D. Heat Shrink Sleeves: 1. Coating System: a. Surface preparation: SP11 Power Tool to Bare Metal or SSPC-SP10, near white abrasive blast. b. Filler Material: (1) Filler material shall adhere to the pipe and heat shrink sleeve. Size and type shall be as recommended by the sleeve manufacturer for type of pipe and joint. (2) Filler mastic for joints subject to weld after backfill shall exceed 500 degrees F melting temperature. c. Heat Shrink Sleeve: (1) Heat shrink, cross-linked polyolefin wrap or sleeve with a mastic sealant, 85-mils nominal thickness, suitable for pipeline operating temperature, as recommended by the manufacturer. (2) Provide standard recovery sleeve for welded or bell and spigot steel pipe joints. High recovery sleeves shall be provided for mechanical or bell and spigot ductile iron pipe, flange joints, and coupling style joints. (3) Width of heat shrink sleeves shall be sufficient to overlap existing coating 2-inches minimum. Overlap on tape coated steel pipe shall be based on a sequential 2-inch wide step from outer wrap to middle wrap to inner wrap. (4) Sleeve shall meet requirements for “Well After Backfill” when allowed and approved by Engineer. d. Coating Manufacturer’s: (1) Canusa, (2) Raychem-Covalence, (3) Or equal. 2. Application: a. Heat shrink sleeves shall be applied to buried or concrete encased pipeline joints only. Application on vault piping or where exposed to the weather will not be allowed. b. Provide filler material for all rolled or Carnegie joints, flanges, and couplings and all step changes greater than 1/8-inch. c. Filler material shall be applied in a manner and of sufficient thickness that no tenting or voids remain under the heat shrink sleeve. d. CONTRACTOR to consider sleeve shrinkage and joint profile in determining sleeve width required. Overlapping of two or more heat shrink sleeves to achieve the necessary width on pipe joints will not be permitted without Engineer approval.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-10 e. All transitions from tape wrap to epoxy or other brush, roller, or spray applied protective coating system shall be coated at the transition with a heat shrink sleeve with minimum 3-inch overlap onto both coating systems.
2.05 SPECIALS, FITTINGS, AND CONNECTIONS
A. Coating and lining application for special sections, connections, and fittings for steel pipe shall conform to coating system and application requirements as specified this section.
B. Specials, fittings, and connections shall be defined as any pipe section with turnouts for blowoffs, interconnects, any valve, or other appurtenances; tees; crosses; wyes; laterals; manholes; mitered angles or elbows; and pipes which require special fabrication that prevents mechanical production application of the specified coating system from end to end of pipe joint.
C. In addition to the items listed as specials, the following items shall also be considered as specials:
1. All pipe joint sections entering a structure. 2. Pipe joints with pass through holes.
D. Hand applied tape coatings will not be permitted on any specials, valves, fittings, connections, and couplings.
E. Specials, fittings, and connections shall be externally coated with a plural component epoxy coating system, applied from end to end of pipe joint on all specials, fittings, and connections.
2.06 EXTERIOR PIPE JOINT FIELD COATING
A. Pipe joints shall be field coated after pipe assembly in accordance with AWWA C216, except as modified this section.
B. Field joint coating shall be compatible with the shop-applied coating system.
C. All joints on pipe shall be coated with a heat shrink coating material.
D. Field joint coating materials shall be as specified for Field Applied Coatings, this section.
2.07 FIELD APPLIED INTERIOR JOINT COATING
A. Mortar Lining: 1. After the backfill has been completed to final grade, the interior joint recess shall be filled with grout. The grout shall be tightly packed into the joint recess and trowelled flush with the interior surface. Excess shall be removed. 2. At no point shall there be an indentation or projection of the mortar exceeding 1/16-inch.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-11 3. With pipe smaller than 24-inches in diameter, before the spigot is inserted into the bell, the bell shall be daubed with grout. The joint shall be completed and excess mortar on the inside of the joint shall be swabbed out.
2.08 REPAIR OF COATINGS AND LININGS
A. General 1. Coating or lining repair materials shall be compatible with the shop-applied coating or lining system and shall be approved by the coating or lining manufacturer. 2. Coating repair materials shall be as required for the coating system and repair classification as defined this section.
B. Coating Repair Materials 1. Heat Shrink Sleeves (major repair): a. Filler Mastic: Provide mastic filler to fill tape void as required. b. Full Wrap Coating: Cross-linked polyolefin wrap with a mastic sealant, 85-mil thickness nominal, suitable for pipeline operating temperature, sleeve material recovery as recommended by the manufacturer. Sleeve length shall provide a minimum of 3 inches overlap onto intact pipe coating. c. Manufacturer’s: Canusa, Raychem (Polyken), or equal
2. Heat-Applied Patches (minor repair) a. Heat applied adhesive, polyolefin backed, mastic coated tape, 12-inches maximum size. b. Patch shall provide a minimum of 2 inches overlap onto intact pipe coating. c. CRP patch as manufactured by Canusa, PERP patch as manufactured by Raychem (Polyken), or equal.
3. Plural Component Epoxy of Polyurethane Coating or Lining a. Major repairs in the shop will be completed using the coating material specified for the coating or the lining. Coating shall be reapplied using plural component spray equipment by a manufacturer certified coating applicator. b. Major repairs in the shop or field shall be completed using heat shrink sleeves as specified this section. c. Coating material for minor repairs shall be single use epoxy or polyurethane kits similar to the existing coating d. Pinhole holidays or adhesion test coating repairs shall be with minor repair coating material specified or fast cure epoxy, such as Protal 7125 as manufactured by North American Denso, Inc.
C. Exposed Pipe Coating System
1. Touch-up repair all damage to the shop applied coats with the specified coating system prior to final coating of the pipeline in accordance with Section 09900, PAINTING.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-12 PART 3 EXECUTION
3.01 ENVIRONMENTAL LIMITATIONS
A. General 1. Products shall comply with federal, state, and local requirements limiting the emission of volatile organic compounds and worker exposure. 2. Comply with applicable federal, state, and local, air pollution and environmental control regulations for surface preparation, blast cleaning, disposition of spent aggregate and debris, and coating application. 3. Do not perform abrasive blast cleaning whenever the relative humidity exceeds 85 percent, whenever surface temperature is less than 5 degrees above the dew point of the ambient air. 4. Do not apply coatings when: a. Surface and ambient temperatures exceeds the maximum or minimum temperatures recommended by the coating manufacturer or these specifications, b. In dust or smoke-laden atmosphere, blowing dust or debris, damp or humid weather, or under conditions that could cause icing on the metal surface. c. When it expected that surface temperatures would drop below 5 degrees above dew point within 4 hours after application of coating. d. Whenever relative humidity exceeds 85 percent. 5. Where weather conditions or project requirements dictate, CONTRACTOR shall provide and operate heaters and/or dehumidification equipment to allow pipe surfaces to be abrasive blasted and coated as specified and in accordance with the manufacturers coating application recommendations. 6. Work activities can be restricted by the ENGINEER until adequate temperature and humidity controls are in place and functioning within the environmental limits specified. 7. Coating applicator shall provide a monitoring system approved by the coating manufacturer that constantly records pipe and coating conditions during coating application. Recorded monitoring parameters shall include pipe temperature, line speed, holiday test and other parameters applicable to the type of coating.
B. Temperature Control 1. In cold weather or if moisture collects on the pipe, preheat pipe to a temperature between 45 and 90 degrees or 5 degrees above dew point, whichever is greater. 2. When temperatures are above or below the coating manufacturers recommended application temperatures, the CONTRACTOR will provide temperature controls as necessary to permit work to precede within the manufacturer’s temperature limitations. 3. Provide tenting, insulating blankets, baffles, or bulkheads as required to zone and control heating or cooling effectiveness. 4. Heating shall be with indirect fired heaters that do not increase humidity levels within the work area. Heaters shall be sized for the area to be heated.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-13 3.02 SURFACE PREPARATION
A. General 1. Inspect and provide substrate surfaces prepared in accordance with these Specifications and the printed directions and recommendations of coating manufacturer whose product is to be applied. 2. Visible oil, grease, dirt, and contamination shall be removed in accordance with SSPC-SP1, solvent cleaning. 3. Surface imperfections such as metal slivers, burrs, weld splatter, gouges, or delaminations in the metal shall be removed by filing or grinding prior to abrasive surface preparation. 4. Protect prepared pipe from humidity, moisture, and rain. All flash rust, imperfections, or contamination on cleaned pipe surface shall be removed by reblasting. 5. Priming and coating of pipe shall be completed the same day as surface preparation.
B. Weld Surface Preparation 1. Requirements: a. Spray applied coating systems do not require weld grinding. b. Welds on tape wrap coated pipe shall be either ground flush or a weld stripe tape applied over the weld, at the pipe fabricator’s option, unless otherwise specified. 2. Weld Grinding: a. Under the weld grinding option, welds higher than 1/32 inch above pipe surface shall be ground to a tolerance of +1/32 inch to 0-inch above the pipe surface as measured on the lowest side of the weld. 3. Weld Stripe Tape: a. Weld stripe tape will be applied to primed metal. b. Tape will either have no polyethylene backing or will be double sided adhesive tape to permit adhesion of the inner corrosion protection layer to the weld stripe tape. c. Apply tape with a pressure roller to fully conform the tape to the weld surface. d. Adhesion of the weld stripe tape shall be as specified for the coating system.
C. Steel Surface Preparation 1. Surface preparation of steel pipe shall be in accordance with SSPC surface preparation standards utilizing the degree of cleanliness specified for the coating system to be applied or as specified herein, whichever is more stringent. 2. Grit and/or shot abrasive mixture and gradation shall be as required to achieve the degree of cleanliness and coating adhesion specified. 3. Pipe cleaned by abrasive blasting with recyclable steel grit and/or shot or other abrasive shall be cleaned of debris and spent abrasive in an air wash separator. 4. Polyurethane coated steel shall have a sharp angular surface profile equal to or greater than the minimum depth specified. 5. After abrasive blasting surfaces and before coating application, the metal surface shall be cleaned of residual dust to a minimum of Grade 2 per ISO Standard 8502-3, Test for the Assessment of Surface Cleanliness. 6. Work shall be performed in a manner that does not permit the cleaned metal surface to rust back or flash rust.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-14 7. Rust back or flash rust shall be fully removed with the steel surface cleanliness equal to the metal surface cleanliness prior to rust back or flash rusting. Determination of the equivalent surface cleanliness shall be at the Engineer’s sole discretion.
3.03 SHOP -APPLIED COATING SYSTEMS
A. Tape Wrap Coating 1. Applicator shall provide a monitoring system approved by the tape manufacturer that constantly records pipe and tape conditions during coating application. Recorded monitoring parameters shall include, but not be limited to, pipe temperature; line speed, primer and tape roll body temperature, and tape tension. 2. Pipe surface temperature shall be between 45 and 120 degrees and 5 degrees above dew point, whichever is greater. 3. Tape roll temperature shall be in accordance with the manufacturer’s recommendations, but shall not be less than 55 degrees for the inner wrap and 65 degrees for the outer wraps. 4. Apply a uniform coat of primer as recommended by the manufacturer without skips, runs, or sags. Allow to properly dry prior to applying the tape as required by the tape manufacturer and as necessary to achieve maximum tape adhesion. Rug type application will not be allowed. 5. If welds are not ground flush, apply a weld stripe tape to longitudinal or spiral pipe welds prior to application of the inner wrap. 6. Tape layers shall be applied continuously with the use of hydro-tension tape stands. Tension shall be maintained between the manufacturer’s minimum and maximum tension recommendations or as required to achieve approximately 2.0 percent reduction in tape width. 7. Inner tape wrap shall adhere tightly to the pipe surface. Coating shall be 100 percent adhering to the metal surface and shall not have any visible damage, wrinkles, voids, disbondment, contamination, or holidays. 8. Tape coating adhesion testing shall be performed on the pipe as specified this section. 9. Holidays testing shall be conducted on the inner layer tape prior to proceeding with subsequent tape layers. All holidays detected shall be primed and patch using coating repair procedures specified herein. 10. Perform coating and lining repairs as specified in this section.
B. Plural Component Epoxy Coating 1. Applicator Qualifications: a. Equipment will be certified by the coating manufacturer to meet the requirements for material mixing, temperature control, application rate, and ratio control for multi-part coatings. b. Equipment not meeting the written requirements of the coating manufacturer shall be rejected for coating application until repairs or replacement of the equipment is made to the satisfaction of the Engineer. c. Personnel responsible for the application of the coating system shall have certification of attendance at the coating manufacturer’s training class within the last three years. The certified applicator shall be present during all coating application work and shall have responsibility for controlling all aspects of the coating application.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-15 2. Pipe surface temperature shall be between 50 and 100 degrees or 5 degrees above dew point, whichever is greater. 3. Coating application shall be performed in an environmentally controlled shop area that meets or exceeds the written environmental application requirements of the coating manufacturer. Application in outdoor conditions will not be acceptable without adequate environmental shelter, environmental controls, and/or dehumidification. 4. Coating adhesion and holidays testing shall be tested as specified this section. 5. Coating manufacturer shall provide to the Engineer a copy of the manufacturer’s coating application quality assurance manual prior to beginning coating application. Strict conformance to the requirements of the manual will be required. Deviation from the requirements of the manual will be grounds for the Engineer to reject the applied coating. 6. Unacceptable Coating Application a. Coating applied under improper environmental conditions will be rejected. b. Pipes that exceed the allowable quantity of coating defects, regardless of size or cause, shall be rejected. c. Coating which fails the adhesion or holiday testing as specified this section shall be rejected. d. Pipe coating that is subject to off ratio application, blistering, or is not applied in conformance with the coating manufacturer’s written instructions or recommendations shall be rejected. 7. Rejected coating shall be removed from the full length of the pipe to bare metal and reapplied using proper application methods in accordance with the coating manufacturer’s written instruction and the requirements of these specifications. 8. Perform coating and lining repairs as specified in this section.
C. Cement Mortar Overcoat Coatings 1. Dielectrically coated steel pipe, when specifically required or specified, shall have a cement mortar overcoat applied over the dielectric pipe coating in accordance with AWWA C205, except as modified herein. 2. Cement Mortar Overcoat: a. Cement mortar overcoat dielectrically coated steel pipe as specified in AWWA C205, except mortar coating shall be applied over exterior pipe coating. b. Mortar coating shall be held back 3 inches, minimum, behind dielectric coating system cut back at joints. 3. Coating Defects: a. Cracking in the mortar “armor” coat less than 1/8-inch in width will be acceptable. b. Disbondment of the cement coating over a dielectric coating system should be anticipated and will not be grounds for repair or rejection of the pipe. c. Losses of cement mortar coating due to impact, movement, or shipping damage shall be repaired in accordance with C205. 4. Joint Coating: a. Joints do not require field application of cement mortar overcoat when properly coated with heat shrink sleeve joint coating system.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-16 3.04 EXTERIOR COATING HOLDBACK
A. Coating holdbacks shall be straight and cut through the full thickness of the coating.
B. Cutbacks shall be completed in a manner that permits field coating of joints in accordance with the manufacturer’s recommendations and as specified herein.
C. Holdbacks shall be as required for pipe joints as listed below. Pipe manufacturer may adjust holdback limits as required for special joint assemblies, and with consideration for the joint coating provided and joint welding requirements.
Tape wrap coating Push-on joint, spigot 4-inches, minimum Push-on, bell Flush with bell end Welded, spigot 3 inches, minimum Welded, Bell 4-inches, minimum Polyurethane coating Push-on joint, spigot 1-inch before centerline of gasket Push-on, bell Flush with bell end Welded, spigot 3 inches, minimum Welded, Bell 4-inches, minimum Extruded polyolefin Welded joints As specified in AWWA C215 Push-on joints Not applied to bell or spigot
D. Holdback Corrosion Protection: 1. Holding primer for corrosion protection of cutbacks or holdbacks shall be compatible with the specified joint coating system and weld after backfill requirements, where applicable. 2. Approved holdback primers are: a. Tnemec Omnithane – Suitable for all joints, except joints subject to weld after backfill b. Tnemec 90E-92 Ethyl Silicate Inorganic Zinc Primer – suitable for all joints, including weld after backfill joints. c. ICI Devoe Cathacoat 304V Ethyl Silicate Inorganic Zinc Primer – suitable for all joints including weld after backfill joints. d. Polyken Tape Primers – Not allowed 3. Primer shall not result in running or melting of the coating or cause toxic fumes when heated during welding on weld after backfill joints. 4. Application and thickness of holding primer shall be in accordance with the coating manufacturer’s recommendations, but shall not impair the clearances required for proper joint installation.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-17 5. Primer application on spigot end of weld after backfill pipe joints shall be held back 1 to 2 inches from end of spigot or as necessary to prevent toxic fumes during field welding. 6. Any corrosion within the holdback areas shall be abrasively blasted to near white metal in accordance with SP10 or power tool cleaned to bare metal in accordance with SP11 prior to applying joint coating.
3.05 PIPE LINING APPLICATION
A. Shop-applied Cement Mortar Lining: 1. Centrifugally line straight sections of pipe. Lining of special pieces or fittings shall be by mechanical, pneumatic, or hand placement. Provide cement mortar lining of uniform thickness. Finish to a smooth dense surface. 2. Steel plate specials larger than 16 inches in diameter shall have lining reinforced with 2-inch by 4-inch No. 13-gage welded steel wire mesh. 3. Centrifugally line straight sections of pipe. Lining of special pieces or fittings shall be by mechanical, pneumatic, or hand placement. Provide cement mortar lining of uniform thickness. Finish to a smooth dense surface. 4. Steel plate specials larger than 16 inches in diameter shall have lining reinforced with 2-inch by 4-inch No. 13-gage welded steel wire mesh. 5. Brace and support pipe during lining application to minimize pipe distortion or vibration. Bracing and supports shall not damage the pipe, coating, or lining. 6. Tightly close ends of pipe and fittings with plastic sheet caps. Plastic end caps shall be of sufficient thickness and strength to resist shipping, handling, and storage stresses. 7. Damage to the cement mortar lining, including disbondment, cracking, or blistering, caused by improper curing, shipping, handling, or installation shall be repaired in accordance with AWWA specifications and to the satisfaction of the Engineer. 8. Other requirements of mortar lining materials and processes: As specified in AWWA C205.
B. Liquid Epoxy Lining: 1. Where epoxy lining is specified or shown on drawings, epoxy lining shall be applied directly to the steel surface after abrasively blasting to SSPC SP-5, White metal blast. 2. Clean and coat the interior of cement mortar lined pipe at insulating joints with two coats of epoxy coating. 3. Epoxy coating applied at insulating joints shall be applied to both sides of the insulating joint for a minimum of one pipe diameter. If only one side of the joint can be coated the coating shall be applied for a minimum of two pipe diameters. 4. Mortar lining shall be allowed to cure 15 days or steam cured not less than 7 days prior to surface preparation of the mortar and epoxy coating application. Hand applied mortar lining shall be allowed to cure a minimum of 15 days or as required to meet the coating manufacturer’s requirements for application on cement or concrete, whichever is greater. 5. Prepared mortar lining by abrasive blasting to remove all laitance and create a suitable anchor profile 6. Mortar lining shall be dry during epoxy lining application. 7. Epoxy coating shall be applied in two coats minimum, at a total coating thickness of 16 mils dry film thickness. Coating applied over cement mortar lining shall be
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-18 applied in a manner that will minimize gassing and pinholes in the completed lining.
3.06 FIELD COATING JOINTS
A. Surface Preparation: 1. All joints shall be prepared as follows: a. Remove all oil and grease contamination from pipe and adjacent coating in accordance with SSPC-SP1, Solvent cleaning. b. Without Holdback Primer: (1) Clean pipe surface and adjacent coating of all corrosion and other foreign contaminates in accordance with SSPC-SP11, Power Tool Cleaning to Bare Metal or abrasive blast joints in accordance with SSPC-SP10, near white metal blast. (2) Clean the full circumference of the pipe and a minimum of 4 inches onto the existing coating. (3) No profile is required with SP-11 preparation and heat shrink sleeve joint coating. c. With Holdback Primer: (1) All joints with a holdback primer shall be prepared by removing all oil and grease in accordance with SSPC-SP1, Solvent Cleaning, followed by spot preparation of visible corrosion or rust in accordance with SSPC-SP11, Power Tool Cleaning to Bare Metal. (2) Clean the full circumference of the pipe and a minimum of 4 inches onto the existing coating. 2. Remove all loose or damage pipe coating at joint and either repair the coating as specified herein or increase the length of the joint coating, where reasonable and practical. 3. Joint bonds shall be installed before application of joint coating as specified in Section 13115, CATHODIC PROTECTION. Joint bonds shall be low profile bonds and all gaps and crevices around the bonds shall be filled with filler mastic. 4. Contractor to electrically test completed joint coating for holidays with high voltage spark tester at Engineer’s direction or if damage to the joint coating occurs.
B. Weld After Backfill’ Joint Requirements:
1. Post welding of joints (weld after backfill) is not allowed, unless approved by the Engineer and the welding procedure approved meets the most current requirements for weld after backfill coating protection, holdback coating temperature resistance, heat input monitoring, and welding procedures. 2. Post-welded or ‘Weld after Backfill’ joints are defined as welded pipe joints that have been coated and backfilled prior to completing interior welds. 3. Post welded joints shall be coated and protected as follows: a. Joint coating shall be Canusa AquaShield heat shrink joint sleeves only. Tape wrapped joints will not be acceptable. b. Provide 6-inch wide Canusa AquaShield protective layer centered over the interior weld location as recommended by the joint sleeve manufacturer. Heat resistant tape will not be acceptable. c. Hold back primer shall be suitable for post weld conditions as specified this section and shall not exhibit any binder breakdown in the heat affected zone that causes loss of joint coating adhesion to the holdback primer.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-19 d. Filler mastic materials shall be high temperature material with 500 degree F melting point. e. Joints shall be fully buried prior to welding, with not less than 12-inch soil cover or flowable fill material on all sides. Sand or flowable fill backfill is preferred for weld after backfill joints. 4. Welding of the joints shall be in conformance with the Section 02570, Steel Pipe, and as modified herein: a. All welding shall be with two or more weld passes as required to meet the specified AWS qualified welding procedures and maximum coating temperature limitations. ‘Weld after Backfill’ procedures on wall thicknesses of ¼ inch or less must be approved by the Construction Manager based on field testing demonstrating the welding procedures can comply with the requirements of this specification. b. Welding speed, amperage, and voltage shall be as required to maintain a maximum heat input of 23,000 joules or a maximum surface temperature at the coating/steel interface of 800 degrees F, whichever is least. c. Maximum weld temperature and duration shall not result in carbonization of the joint coating adhesive. Carbonization is defined as the loss of volatile organic compounds that result in loss of tackiness, adhesion to the steel, and corrosion protection properties. d. Finished joint coating shall not have any visual creases or folds in the joint coating backing material that extends through both the inner protective layer and outer joint sleeve. 5. If Contractor elects to post-weld any joints, Contractor shall demonstrate that the joint welding procedures will not significantly damage the coating by fully excavating the first two joints for evaluation of the joint coating condition. Engineer will randomly select up to three additional post-welded joints for excavation by Contractor for evaluation of joint coating condition. Joint coating will be destructively evaluated by the Engineer. Contractor will removed and replace joint heat shrink sleeve upon completion of the evaluation. 6. In the event that any excavated post welded joint exhibits any heat related damage as defined herein, Contractor shall modify and test a new post welding procedure prior to completing any additional post-welded joints. Contractor shall demonstrate that the revised joint welding procedure will not significantly damage the coating by repeating the weld after backfill evaluation requirements defined this Section, including excavation of the three additional randomly selected joints for destructive evaluation.
C. Heat Shrink Sleeve Joint Coating: 1. Store, handle, and apply field heat shrink sleeve coatings in accordance with AWWA C216 and these specifications. 2. Store sleeves in shipping box until use is required. Keep dry and sheltered from exposure to direct sunlight. Store off the ground or concrete floors and maintain at a temperature between 60 and 100 degrees as recommended by the sleeve manufacturer. 3. Metal surface shall be free of all dirt, dust, and surface corrosion prior to sleeve application. 4. Complete surface preparation of joint as specified. 5. Preheat pipe uniformly as recommended by the sleeve manufacturer. Monitor pipe temperature using a surface temperature gauge, infrared thermometer, or color changing crayons. Protect preheated pipe from rain, snow, frost, or moisture with tenting or shields and do not permit the joint to cool.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-20 6. Fill all cracks, crevices, gaps, and step changes greater than 1/8 inch with filler mastic. Application of filler material shall be in accordance with the manufacturer’s instructions for the full circumference of the pipe and in a manner that does not cause tenting of the applied sleeve. 7. Apply heat shrink sleeve when it is at a minimum temperature of 60 degrees and while maintaining the pipe temperature above the preheat temperature specified. Apply sleeve in accordance with the manufacturer’s instructions and center the sleeve over the joint to provide a minimum 2-inch overlap onto the existing pipe coating. 8. Completed joint sleeve shall be fully bonded to the pipe and existing coating surface without voids. Mastic beading shall be visible along the full circumference of the sleeve. There shall be no wrinkling or excessive burns on the sleeves. Sleeves that do not meet these requirements shall be removed and the joint recoated as directed by the Engineer. Minor damage may be repaired using heat applied patch material as specified for minor coating repairs. 9. Allow the sleeve to cool before backfilling. In hot climates, provide shading from direct sunlight. Water quenching will be allowed only when permitted by the sleeve manufacturer. 10. Heat shrink joint coatings which have become wrinkled or disbonded because of prolonged exposure to UV light or thermal cycling shall be removed and replaced. 11. Double coating of defective or damaged heat shrink coatings will not be permitted. Any double coated heat shrink sleeves shall be immediately rejected and Contractor shall remove the existing coating and recoat the joint.
D. Cement Mortar Coating: 1. Pipe joints on cement mortar over coated steel pipe do not require cement mortar coating.
3.07 REPAIR OF COATING AND LININGS
A. General: 1. All areas where holidays are detected or coating is visually damaged, such as blisters, tears, rips, bubbles, wrinkles, cuts, or other defects shall be repaired. Areas where no holidays are detected, but are visually damaged shall also be repaired. 2. Maximum defects allowable shall be as specified herein for the coating system.
B. Tape Wrap Coating Repairs: 1. General: a. No more than five repairs per joint of pipe will be permitted with tape wrap coating, excluding adhesion test damage. The coating on any pipe with more than five coating repairs or with more than two areas of coating damage greater than five square feet will be rejected. b. Pipes exceeding the maximum number or size of coating defects shall be stripped, reblasted, and recoated. c. Pipe arriving in the field with defects or repairs exceeding the maximum number or size of coating defects will be returned to the shop for recoating at the Contractor’s expense. d. The number of layers and total thickness of the tape repair coating shall be the same as the shop-applied coating; unless heat applied coating materials is used.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-21 e. Wipe the area to be repaired with solvent for a minimum distance of 4 inches outside the damaged area.
2. Defect Size: a. Minor repairs - repairs that are less than 8 inches in the greatest dimension, measured after cutout of damaged tape layers. Damage to the inner tape layer will be considered minor only if repairs are made using heat applied patch materials. b. Major repairs - repairs that exceed 8-inches in the greatest dimension or where damage to the inner tape layer has occurred and hand applied tape repairs will be used.
3. Minor Repairs: a. Complete minor repairs using a heat applied coating patch material. b. Cut patch material to overlap onto the undamaged coating a minimum of 2 inches on all sides with 1-inch radius on each corner of the patch. c. Carefully remove damaged layers by cutting the coating with a sharp knife without cutting or damaging the inner wrap. d. Cut middle and outer layers in stepped fashion to expose 1-inch or more of the underlying tape layer for the circumference of the repair.
4. Major Repairs (Over 24-inches Diameter): a. Cigarette wrap coating repairs shall be with heat shrink sleeves as specified for joints. b. Carefully remove damaged layers by cutting the coating with a sharp knife without cutting or damaging the inner wrap. c. Holiday test the inner wrap and if a holiday is detected cut outer layers back to fully exposed the holiday(s) and retest for holidays. d. Cut middle and outer layers in stepped fashion to expose 1-inch or more of the underlying tape layer for the circumference of the repair. e. Width of sleeve shall be the width of the damaged area plus 4-inch overlap. Multiple sleeves may be used for larger repairs, but must be overlapped a minimum of 2 inches.
5. Major Repairs (24-inch Diameter or Less) a. Cigarette wrap repairs on pipe less than 24-inches with either hand applied tapes as specified or heat shrink sleeves as specified for major repairs on pipe over 24-inches in diameter at the Contractor’s option. b. Carefully remove damaged layers by cutting the coating with a sharp knife without cutting or damaging the inner wrap. Holiday test the inner wrap and if a holiday is detected apply one extra layer of repair tape. c. Clean surfaces by solvent wiping and applying primer over the inner tape layer for a minimum of 6-inches onto the outer wrap in all directions. d. Apply first layer of repair coating, over lapping 1-inch or more onto undamaged coating in all directions. On larger areas, lap the repair tape within a minimum of 1-inch overlap, offsetting the overlap from the previous layer overlap, until the area is properly covered. e. Repeat for each tape layer damaged with each succeeding layer applied at 90 degrees to the preceding layers and overlapping onto the undamaged coating a minimum of 2-inches. f. Apply the last tape layer, use the cigarette wrap method for the full pipeline circumference covering all previous repair layers and overlapping a minimum
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-22 of 2-inches onto undamaged coating. The ends of the cigarette wrap shall be pointed downward.
C. Plural Component Epoxy Coating or Lining Repairs 1. General a. Complete coating or lining repairs in accordance with the coating manufacturers written instructions and these specifications, whichever is stricter. 2. Defect Size: a. Minor repairs - repairs that are less than 8-inches in the greatest dimension. b. Major repairs - repairs that exceed 8-inches in the greatest dimension. 3. Maximum Quantity of Defects Allowed: a. Coating or lining repairs on any joint of pipe shall not exceed 1.5 per 100 square feet of surface area. (1) Two or more minor repairs within a 6-inches diameter circle will be considered a single repair. (2) Repairs for adhesion testing will not be included in the total number of repairs. b. Major repairs shall not exceed three per pipe joint and the combined area shall not be greater than 30 percent of the pipe. c. Pipes exceeding the maximum number or size of coating defects shall be stripped of coating, reblasted, and recoated. d. Pipe arriving in the field with defects or repairs exceeding the maximum number or size of coating defects will be returned to the shop for recoating at the contractor’s expense. 4. Minor Repairs: a. Surface Preparation: Clean and feather the defect by power tool sanding with 80 grit or coarser sandpaper to roughen the existing coat and feather the edges of the defect for a minimum of 2-inches around the defect. b. Shop repair Materials: (1) Single use polyurethane coating kits that controls mix ratio. (2) Two component, fast cure epoxy coating, in controlled mix ratio packaging. (a) Protal 7125, North American Denso Inc, or equal (b) Or equal. (3) Coating Manufacturer’s polyurethane coating repair products subject to Engineer approval. c. Field Repair Materials: (1) Heat applied coating materials; CRP Patch, Canusa; PERP Patch, Tyco Adhesives, or approved equal. (2) Two component, fast cure epoxy coating, in controlled mix ratio packaging. (a) Protal 7125, North American Denso, Inc, (b) Or equal. (3) Single use polyurethane coating kits using single use packaging that controls mix ratio. (4) Coating Manufacturer’s polyurethane coating repair products subject to Engineer approval. d. Clean and feather the defect by power tool sanding with 80 grit or coarser sandpaper to roughen the existing coating and feather defect edges minimum of 2-inches.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-23 e. Apply a single coat of the specified patch coating material at the specified coating thickness. f. Repair coating adhesion shall be 50 percent of the specified coating adhesion.
5. Major Repairs: a. Surface Preparation: (1) The metal surface and surrounding coating shall be abrasively blasted in accordance with SSPC-SP10, near white metal, or to equal in cleanliness and profile as the original surface preparation. (2) Existing coating shall be feathered and roughened to the equivalent of 40 grit sandpaper. b. Shop Repair Materials: (1) Same material as the pipeline coating or lining and shall be applied by using plural component spray equipment. c. Field Repair Materials: (1) Same material as the pipeline coating or lining and shall be applied by using plural component spray equipment. (2) Heat shrink sleeves as specified for pipeline joints. d. One coat of the specified original coating material shall be applied over the repaired surface at the specified thickness. e. Repair adhesion shall be equal to the specified coating adhesion.
3.08 INSPECTION AND TESTING
A. General 1. Applicator shall inspect and test the coating system in accordance with referenced standards and these specifications, whichever is more stringent. 2. Quality control testing as specified in AWWA standards are minimum industry standards and it is the intent of this specification to provide a higher level of quality control for the objective of achieving maximum coating performance. If any conflict between this specification and referenced standards occurs, the more stringent requirement shall apply and any interpretation of this requirement or results shall be with the objective of achieving maximum coating performance. 3. The frequency of the testing shall be determined by the applicator, but shall not be less than the requirements of this specification.
B. Surface Profile Testing 1. Surface profile of abrasive blasted surfaces to be tested with “Press-O-Film” tester tape or equivalent in accordance with NACE RP287. 2. Tester tape shall be suitable for the intended profile height. 3. Profile shall be measured to a minimum tolerance of 0.1 mils, maximum. 4. Electronic surface profilometer shall be used, where deemed necessary, to verify tester tape measurements.
C. Adhesion Testing 1. General a. Adhesion testing shall be conducted at the shop prior to shipment. Pipe shipped without adhesion testing will be field-tested. Pipe rejected in the field will be returned to the shop for repair at the sole expense of the Contractor.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-24 b. Coating adhesion testing shall be conducted on each pipe lot coated. The quantity of coating adhesion tests shall be the greater of the following: (1) Two pipes will be tested for the first 3,000 square feet of coating application plus on additional pipe for each increment of 2,000 square feet of coating application in excess of the first 3,000 square feet (2) Not less than 25 percent of each pipe produced within a lot. c. A pipe lot is defined as the quantity of pipe that is coated by a single crew within a 12 hour or less work shift. d. The pipe coating applicator shall repair all coating damage from shop adhesion testing. Contractor shall be responsible for coating repairs for all field adhesion testing. e. Adhesion tests will be performed not less than 24 hours after coating application. Tests conducted prior to 24-hours will be acceptable only if the test meets or exceeds the adhesion criteria specified and the test was requested by the pipe fabricator. f. Pipe for adhesion testing shall be randomly selected. g. Owner or Owner’s Representative has the right to conduct additional adhesion testing as deemed necessary to assure the pipe meets or exceeds the requirements of this specification at any time and location. h. Prior to beginning any QA/QC testing, the pipe fabricator, coating manufacturer, and Engineer shall review dolly attachment procedures, adhesion test procedures, and data recording requirements for the project and ensure that test personnel are qualified and capable of performing the testing in accordance with required test standards and these specifications.
2. Rejection of Pipeline Coating or Lining a. Each pipe that fails the adhesion criteria, as defined this section, shall be rejected. b. If any pipe within a lot that fails to meet the adhesion criteria specified for the coating type, the pipe coating will be rejected and all pipes within the lot will be classified as rejected. Each remaining pipe within the rejected pipe lot will then be individually tested and rejected on a pipe-by-pipe basis in conformance with the test procedures and criteria specific to the coating type. c. All rejected pipe shall have the coating fully removed from the pipe and the pipe abrasive blasted and recoated.
3. Tape Coating Adhesion Testing: a. Adhesion Acceptance Criteria: (1) Inner tape coating shall have an adhesion to substrate of 20 pounds per inch width, minimum, for steel pipe when tape is pulled in a continuous manner at an angle of 180 degrees to the pipe surface. . b. Test Procedures (1) Adhesion testing shall be conducted prior to application of the cement mortar overcoat, where applicable. Pipe that has been mortar coated prior to adhesion testing shall have the mortar coating removed by the Contractor as directed by the Engineer and of sufficient dimensional area to permit the adhesion test to be conducted. (2) Adhesion tests shall be conducted at temperatures above 60 degrees and less than 75 degrees. (3) Pulling tension shall be continuous, without stopping, and monitored throughout the length of the pull, which shall be not less than 12-inches in length.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-25 (4) Adhesion test shall be prepared by making two parallel cuts through the coating, 1-inch apart, of sufficient length for the test pull. Peel the coating back at one end and attach the tension scale to the coating with a suitable clamp. Mark the coating at one (1) inch increments from 0 to 12-inches. (5) The pull tension shall be recorded for each inch of pull. The two highest and two lowest readings shall be discarded and the remaining values averaged. Pull speed shall be between 5 and 10 seconds per inch. If significant elongation of the tape backing occurs, pull speeds may exceed 10 seconds per inch provided the minimum adhesion rating can still be achieved. c. Adhesion Pull Records and Evaluation (1) Failure shall be by cohesive failure of the adhesive only. Delamination failure, defined as separation of the adhesive from the backing material, will result in rejection of the tape lot. (2) Intermittent skip failures will be counted as zero pounds of adhesion and included in the calculations for average coating adhesion. (3) Adhesive failure, defined as separation of the adhesive from the metal substrate, will be rejected. (4) Pipe that fails the test by delamination will be retested on two other pipes within the same lot of coated pipe. Failure of any two pipes within the lot will result in rejection of all pipes coated with the rejected tape lot.
4. Plural Component Epoxy Adhesion Testing: a. General: (1) Adhesion testing shall be performed in accordance with this specification section. (2) Adhesion testing procedures and evaluations per AWWA C210 are specifically excluded under this specification. b. Coating and Lining Adhesion Acceptance Criteria (1) Coating applied to each pipe is acceptable if first dolly pull test exceeds 1,750 psi, minimum. (2) If first dolly pull is less than 1,750 psi, two additional tests shall be performed with acceptance based on “Best of Three” evaluation method defined herein. c. Pipe Lot Performance Criteria: (1) Each lot of coated pipe shall be evaluated for general coating application based a median value for all coating or lining adhesion tests performed on a lot of pipe, which shall be greater than 2,000 psi. (2) Any pipe lot failing the Pipe Lot Performance Criteria shall be classified as rejected until 100 percent of the pipe within the pipe lot has been tested for adhesion. Each pipe that fails the coating adhesion criteria shall be rejected. d. Test Procedures (1) Coating adhesion testing shall be with self-aligning pneumatic pull off equipment, such as the Delfesko Positest AT-A, and test procedures in accordance with ASTM D4541, except as modified in this section. (a) All adhesion tests shall be performed at an applied load rate of 100 psi per second, plus or minus 10 psi. Automatic pull rate adhesion test equipment shall be used. (b) Adhesion tests shall be based on the ASTM D4541 using standard 20 mm dollies.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-26 (c) Adhesion testing shall be based on three tests. All three tests shall be conducted by the same person, test equipment, and test procedure, and must be completed within a 30 minute period. (d) All adhesion tests shall be conducted within an area not to exceed 6-inches by 6-inches. (e) All dollies shall be scored to metal substrate using manual methods and tools, normal to the pipe surface, and in a manner that does not stress or over heat the coating. (f) All adhesion tests shall be performed to glue or coating failure or test termination, whichever comes first. (2) Dollies for adhesion testing shall attached to the coating surface using an two part epoxy or cyanoacrylate glue and allowed to cure for a minimum of 12 hours before testing or until full cure, whichever is greater. Glue type used shall be determined by the pipe fabricator and coating manufacturer for the pipe diameter, temperatures, and environmental conditions. (3) Adhesion testing shall be performed at temperatures between 55 and 90 degrees F or at temperatures as recommended by the coating manufacturer. Testing up to 115 degrees F or below 45 degrees will be permitted if tests can demonstrate no statistically detectable effect on test results and subject to Coating Manufacturer and Engineer approval. e. Adhesion Test Evaluation and Records (1) The “Best of three” evaluation method shall be defined as two of three test values less than the Acceptance Criteria, which shall result in rejection of the pipe coating. (2) All adhesion tests shall be considered as valid and suitable for acceptance or rejection of the coating, except where retesting is allowed. (3) Adhesion test failure shall be by adhesive or substrate and cohesive failure as defined below: (a) Adhesive or substrate failure is defined as a percentage of separation of the coating from the steel substrate or between distinct coating layers. (b) Cohesive failure is defined as a percentage of failure within the coating, resulting in coating remaining both on the steel substrate and test dolly. (4) Retesting of coating adhesion tests will be allowed when any test is glue failure at 25 percent or more of dolly surface area and the test value is less than the Acceptance Criteria or the Minimum Criteria. (5) All coating adhesion retesting shall be within the same 6-inch by 6-inch test area as the original adhesion testing. (6) Disputed adhesion tests shall be retested as defined for adhesion retesting. Dolly attachment and adhesion retesting shall be witnessed by the Owner’s representative. (7) Adhesion tests will be conducted on pipe coating and lining independently and will be accepted or rejected independently. (8) Records of all adhesion tests shall be maintained in an electronic spreadsheet that includes the following information: (a) Pipe identification, (b) Pipe coating date, (c) Adhesion test date, (d) Surface tested (interior or exterior), (e) Surface temperature at time of test,
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-27 (f) Coating thickness, (g) tensile force applied, (h) Applied load rate per second, (i) Mode of failure, and (j) Percentage of failure types, previously defined, relative to dolly surface area, (k) Dolly size and attachment glue used. (l) If different coatings are tested, the records shall include coating manufacturer and product number. f. Adhesion Test Repairs (1) Fabricator or contractor to complete adhesion repairs as specified this section. (2) Repair patches on the polyurethane coating shall be randomly selected for adhesion testing in a manner as described herein and at the discretion of the coating inspector conducting the adhesion tests. Adhesion of repairs shall be as specified for the type of repair.
D. Holiday Testing 1. Holiday test the inner layer of tape wrap coatings after application and prior to the subsequent tape layer in accordance with AWWA C214 and NACE Standard RP-0274. 2. Holiday tests on epoxy or polyurethane coatings or linings will be conducted on the completed coating or lining after cure or 24-hours, whichever is less, using a high voltage spark test in accordance with NACE Standard RP-0274 and these specifications. 3. Coating thickness used for high voltage holiday testing setting shall be the minimum specified coating thickness.
E. Dry Film Thickness Testing 1. Coatings shall be tested for dry film thickness using a properly calibrated magnetic pull off, eddy current, or ultrasonic equipment. 2. Coating thickness measurements shall be conducted as necessary and without limitation. Testing conformance to the requirements of SSPC PA-2 is specifically excluded from this specification.
3.09 HANDLING, TRANSPORTATION, AND STORAGE
A. Pipe shall be handled in such a manner as to protect the pipe and coating from damage.
B. Coated pipe shall not be shipped or installed until coating has developed full adhesion and cure.
C. During coating application, storage, loading, transportation, unloading, laying and installation, every precaution shall be taken to protect and prevent damage to pipe, lining, and coating. Forklift equipment shall have all bearing surfaces padded with suitable padding material. Lift pipe with web slings a minimum of 12-inch wide and of a type that will not damage the coating. Metal chains, cable, tongs, forklifts or other equipment likely to damage the coating will not be permitted. Dragging or skidding of pipe on grade or in the trench will not be permitted.
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-28 D. Provide transportation vehicles with padded bolsters between each layer of pipe and heavy padding under load ties. Bolsters shall be curved to fit the outside of the pipe and 12 inches wide, minimum. All pipe contact locations shall be heavily padded with carpet and strips of the outer tape wrap material (adhesive side against the carpet) during shipment to the project site and from the storage yard to the point of installation.
E. Pipe shall not be stored on rocks, gravel, or other hard materials that might damage the coating. Provide padded 12-inch wide skids and chucks, sand bags, select loamy or sand berms, or suspended from cutback ends, where possible, to minimize coating damage. Pipe shall not be laid on asphalt without suitable padding at all contact points.
F. Pipe shall not be stored on rocks, gravel, or other hard materials that might damage the coating. Provide padded 12-inch wide skids and chucks, sand bags, select loamy or sand berms, or suspended from cutback ends, where possible, to minimize coating damage. Pipe shall not be laid on asphalt without suitable padding at all contact points.
G. Pipe shall be inspected by the CONTRACTOR at the project site for damage. Any damage to the pipe, lining, or coating shall be repaired as directed if, in the opinion of the ENGINEER, a satisfactory repair can be made; otherwise, the damaged section shall be replaced at the sole expense to the CONTRACTOR.
H. No metal tools or heavy objects shall be permitted to come into contact unnecessarily with the finished coating. Workmen shall not be permitted to walk on the coating except when absolutely necessary and approved by the Engineer. When permitted, shoes with rubber or composition soles and heels or other suitable footwear that will not damage coating shall be used.
I. Long-term Exposure:
1. Pipe shall either be provided with UV inhibitor for lengthy of above grade exposure or covered to prevent UV degradation of outer wrap. 2. Amount of UV stabilizers required will depend on the project location, laying schedule, anticipated length of exposure, and type of coating. 3. Manufacturer shall be consulted for recommended UV inhibitors requirements. 4. Protective covering can be colored plastic sheeting, canvas, or other UV blocking material. Clear plastic sheets are not acceptable. 5. Areas of coating that display UV degradation shall be removed and repaired at sole cost of the CONTRACTOR.
END OF SECTION
BCA JVWCD PIPELINE COATING AND LINING CENTRAL PIPELINE PROJECT PAGE 09910-29
DIVISION 10 SPECIALTIES
SECTION 10425 SIGNS
PART 1 - GENERAL
1.1 SUMMARY OF WORK
A. This Section includes the following types of signs:
1. Panel signs. a. Interior room identification signs. b. Handicap accessibility signage. c. Parking signs (handicapped). d. Handicap entry signs. e. Site directional signs. f. Maximum occupancy load signs. 2. Dimensional letters and numbers. 3. Building address.
1.2 CONTRACTOR SUBMITTALS
A. General: Submit the following according to the Conditions of the Contract and Division 1 Specification Sections.
B. Product data for each type of sign specified, including details of construction relative to materials, dimensions of individual components, profiles, and finishes.
C. Shop drawings showing fabrication and erection of signs. Include plans, elevations, and large-scale sections of typical members and other components. Show anchors, grounds, layout, reinforcement, accessories, and installation details.
1. Provide message list for each sign required, including large-scale details of wording and lettering layout. 2. For signs supported by or anchored to permanent construction, provide setting drawings, templates, and directions for installation of anchor bolts and other anchors to be installed as a unit of Work in other Sections. 3. Templates: Furnish full-size spacing templates for individually mounted dimensional letters and numbers. 4. Furnish full-size layouts for metal plaques.
D. Samples: Provide the following samples of each sign component for initial selection of color, pattern and surface texture as required and for verification of compliance with requirements indicated.
1. Samples for selection of color, pattern, and texture: a. Cast Acrylic Sheet and Plastic Laminate: Manufacturer's color charts consisting of actual sections of material including the full range of colors available for each material required.
BC&A SIGNS JVWCD PAGE 10425-1 CENTRAL PIPELINE PROJECT b. Aluminum: Samples of each finish type and color, on 6-inch-long sections of extrusions and not less than 4-inch squares of sheet or plate, showing the full range of colors available.
1.3 QUALITY ASSURANCE
A. Sign Fabricator Qualifications: Firm experienced in producing signs similar to those indicated for this Project, with a record of successful in-service performance, and sufficient production capacity to produce sign units required without causing delay in the Work.
B. Single-Source Responsibility: For each separate sign type required, obtain signs from one source of a single manufacturer.
C. Handicapped Accessibility: Provide signs which are in conformance with the requirements of ANSI A117.1-2003 and the Americans with Disabilities Act of 1990 (ADA).
D. Design Concept: The Drawings indicate sizes, profiles, and dimensional requirements of signs and are based on the specific types and models indicated. Sign units by other manufacturers may be considered provided deviations in dimensions and profiles do not change the design concept as judged by the Architect. The burden of proof of equality is on the proposer.
1.4 DELIVERY AND HANDLING
A. Delivery: Provide protective covering or crating as recommended by the manufacturer to protect sign components and surfaces against damage during transportation and delivery.
B. Handle signs carefully to prevent breakage, surface abrasion, denting, soiling, and other defects. Comply with the manufacturer's written handling instructions for unloading components subject to damage.
1. Inspect sign components for damage on delivery. 2. Do not install damaged sign components. 3. Repair minor damage to signs, provided the finished repair is equal in all respects to the original work and is approved by Architect; otherwise, remove and replace damaged sign components.
1.5 PROJECT CONDITIONS
A. Field Measurements: Take field measurements prior to preparation of shop drawings and fabrication to ensure proper fitting. Show recorded measurements on final shop drawings. Coordinate fabrication schedule with construction progress to avoid delay.
1.6 WARRANTY
A. General Warranty: The special warranty specified in this Article shall not deprive the Owner of other rights the Owner may have under other provisions of the Contract Documents and shall be in addition to, and run concurrent with, other warranties made by the Contractor under requirements of the Contract Documents.
BC&A SIGNS JVWCD PAGE 10425-2 CENTRAL PIPELINE PROJECT B. Fiberglass Panel Sign Warranty: Submit a written warranty, signed by manufacturer, agreeing to repair or replace fiberglass panels that fail during the specified warranty period. Failures include, but are not limited to, the following:
1. Coating degradation. 2. Chalking. 3. Fading. 4. Fiberglass delamination or cracking.
C. Warranty Period: 5 years.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated in the Work include, but are not limited to, the following:
1. Manufacturers of Panel Signs: a. ABC Architectural Signing System. b. ASI Sign Systems, Inc. c. Best Manufacturing Company. d. Spanjer Brothers, Inc. e. Vomar Products, Inc. 2. Manufacturers of Dimensional Letters: a. ASI Sign Systems, Inc. b. Metal Arts. c. Metallic Arts, Inc. d. The Southwell Company. e. Spanjer Brothers, Inc. f. Vomar Products, Inc.
2.2 MATERIALS
A. Steel Tubing: Cold-formed steel tubing conforming to ASTM A 500, Grade B, hot-dip galvanized after fabrication with a minimum of 2.0 oz. of zinc/sq. ft. (610 g of zinc/sq. m) of surface area conforming to ASTM A 123.
B. Fiberglass: Molded, seamless, thermosetting, glass-fiber-reinforced polyester panels in sizes and thicknesses indicated, with a minimum tensile strength of 15,000 psi (103 MPa) when tested according to ASTM D 638 (ASTM D 638M) and with a minimum flexural strength of 30,000 psi (207 MPa) when tested according to ASTM D 790 (ASTM D 790M).
C. Cast Acrylic Sheet: Provide cast (not extruded or continuous cast) methyl methacrylate monomer plastic sheet, in sizes and thicknesses indicated, with a minimum flexural strength of 16,000 psi when tested according to ASTM D 790, with a minimum allowable continuous service temperature of 176 deg F (80 deg C), and of the following general types:
1. Opaque Sheet: Where sheet material is indicated as "opaque," provide colored opaque acrylic sheet in colors and finishes as selected from the manufacturer's standards.
BC&A SIGNS JVWCD PAGE 10425-3 CENTRAL PIPELINE PROJECT
D. Aluminum Castings: Provide aluminum castings of alloy and temper recommended by the sign manufacturer for the casting process used and for the use and finish indicated.
E. Fasteners: Use concealed fasteners fabricated from metals that are not corrosive to the sign material and mounting surface.
F. Anchors and Inserts: Use nonferrous metal or hot-dipped galvanized anchors and inserts for exterior installations and elsewhere as required for corrosion resistance. Use toothed steel or lead expansion bolt devices for drilled-in-place anchors. Furnish inserts, as required, to be set into concrete or masonry work.
G. Concrete for Post Holes: Mix portland cement complying with ASTM C 150, aggregates complying with ASTM C 33, and clean water to obtain concrete with a minimum 28-day compressive strength of 2500 psi (17 MPa). Use at least 4 sacks of cement/cu. yd. (225 kg of cement/cu. m), 1-inch (25-mm) maximum-size aggregate, maximum 3-inch (75-mm) slump, and 2 to 4 percent entrained air.
2.3 PANEL SIGNS
A. General: Provide panel signs that comply with requirements indicated for materials, thicknesses, finishes, colors, designs, shapes, sizes, and details of construction.
1. Produce smooth panel sign surfaces constructed to remain flat under installed conditions within tolerance of plus or minus 1/16 inch1.5 mm measured diagonally.
B. Basis-of-Design Product: ASI Sign Systems, Inc.; ASI Tactile Graphics Plaque Sign System or a comparable product of one of the following:
1. Available Manufacturers: a. APCO Graphics, Inc. b. Best Manufacturing Co. c. Mohawk Sign Systems.
C. Sign Face: High impact aluminum tri-hydrate filled polyester acrylate resin, pressure molded into a single polymerized component, using manufacturers standard co-molding process.
D. Unframed Panel Signs: Fabricate signs with edges mechanically and smoothly finished to comply with the following requirements:
1. Edge Condition: Square cut. 2. Corner Condition: Square. 3. Depth: 0.25 inch thickness. 4. Panel Appearance: As selected by Architect. 5. Color: As selected by Architect from manufacturers full range of colors. 6. Surface Texture: As selected by Architect. 7. Letter Style: Arial. 8. Letter Height: As scheduled.
BC&A SIGNS JVWCD PAGE 10425-4 CENTRAL PIPELINE PROJECT E. Brackets: Fabricate brackets and fittings for bracket-mounted signs from extruded aluminum to suit panel sign construction and mounting conditions indicated. Background chassis shall be concealed by modules and accessories.
F. Graphic Content and Style: Provide sign copy that complies with requirements indicated in the Sign Schedule for size, style, spacing, content, mounting height and location, material, finishes, and colors of signage.
1. Provide signage indicating handicap entry at each set of entry doors into facility. 2. Provide one wall mounted sign per door or set of doors throughout building. a. Provide signs with cutouts and removable inserts (maximum of three (3) per sign) with permanent ADA text. 3. Provide maximum occupancy load signs in assembly rooms as required by code.
G. Tactile and Braille Copy: Manufacturer's standard process for producing copy complying with ADA Accessibility Guidelines and ICC/ANSI A117.1. Text shall be accompanied by Grade 2 braille. Produce precisely formed characters with square cut edges free from burrs and cut marks.
1. Raised-Copy Thickness: Not less than 1/32 inch0.8 mm.
H. Changeable Message Inserts: Fabricate signs to allow insertion of changeable messages in the form of transparent covers with paper inserts printed by Owner.
1. Furnish paper and software for creating text and symbols for IBM compatible computers for Owner production of paper inserts. 2. Furnish paper cut-to-size for changeable message insert.
I. Colored Coatings: For copy and background colors, provide Pantone Matching System (PMS) colored coatings, including inks and paints that are recommended by acrylic manufacturers for optimum adherence to acrylic surface and are nonfading for application intended.
J. Applied Copy: Die-cut characters from vinyl film of nominal thickness of 3 mils (0.076 mm) with pressure-sensitive adhesive backing. Apply copy to exposed face of panel sign, glass, doors, or wall surfaces as indicated.
K. Back-up Sign Panel: Provide back-up blank sign panels at all glass mounted sign locations. Back-up sign panel shall match finished sign face and shall be used to conceal sign attachment to glass. Back-up blank sign panels shall be used or located as directed by Architect.
2.4 EXTERIOR DIRECTIONAL AND PARKING SIGNS
A. Panel Signs: Comply with requirements indicated for materials, thicknesses, finishes, colors, designs, shapes, sizes, and details of construction.
1. Produce smooth, even, level sign panel surfaces, constructed to remain flat under installed conditions within a tolerance of plus or minus 1/16 inch measured diagonally.
BC&A SIGNS JVWCD PAGE 10425-5 CENTRAL PIPELINE PROJECT B. Steel Posts: 0.120-inch- (3.0-mm-), galvanized, seamless, square steel posts in length adequate for mounting method specified. Include post caps, fillers, spacers, junction boxes, access panels, and related accessories required for a complete installation. Comply with the following requirements for post shape, finish, and mounting method indicated:
1. Post Size: 2 by 2 inches (50 by 50 mm) square. 2. Post Mounting Method: Provide sign posts of length required for permanent installation by direct-burial mounting method.
C. Sign Panels: Provide smooth, even, level sign panel surfaces constructed to remain flat under installed conditions within a tolerance of plus or minus 1/16 inch (1.5 mm) measured diagonally from corner to corner.
1. Unframed Single-Sheet Panels: Provide unframed single-sheet sign panels with edges mechanically and smoothly finished to conform to the following: a. Panel Material: 0.125-inch- (3.2-mm-) thick fiberglass sheet. 1) Panel Finish: Manufacturer's standard semigloss finish with UV inhibitors. b. Edge Condition: Square cut. c. Corner Condition: Square corners.
D. Graphic Content and Style: Provide sign copy that complies with the requirements indicated for size, style, spacing, content, position, material, finishes, and colors of letters, numbers, and other graphic devices.
1. Copy Embedded in Fiberglass Panels: Apply computer-generated adhesive graphics to panel as a masking material. Apply acrylic polyurethane background- color flood coats, 0.015-inch (0.4-mm) minimum thickness. Include UV inhibitors. Remove masking material. a. Provide signage indicating handicap parking at all handicap parking spaces. b. Provide directional signage on site for bus, automobile and pedestrian access.
E. Fabrication: Provide manufacturer's standard single-post, single-panel-type post and panel signs. The completed sign assembly shall consist of a message panel supported on 1 post. Comply with requirements indicated for materials, thicknesses, finishes, colors, designs, shapes, sizes, and details of construction. 1. Allow for thermal movement resulting from a maximum ambient temperature change (range) of 100 deg F (38 deg C). Design, fabricate, and install post and panel sign assemblies to prevent buckling, opening up of joints, and overstressing of welds and fasteners. 2. Base design on actual surface temperatures of metals due to both solar heat gain and nighttime-sky heat loss. a. Welded Connections: Comply with AWS standards for recommended practices in shop welding. Provide welds behind finished surfaces without distortion or discoloration of exposed side. Clean exposed welded surfaces of welding flux and dress on exposed and contact surfaces. b. Mill joints to a tight, hairline fit. Form joints exposed to the weather to exclude water penetration. c. Preassemble signs in the shop to the greatest extent possible to minimize field assembly. Disassemble signs only as necessary for shipping and
BC&A SIGNS JVWCD PAGE 10425-6 CENTRAL PIPELINE PROJECT handling limitations. Clearly mark units for reassembly and installation, in a location not exposed to view after final assembly. d. Conceal fasteners if possible; otherwise, locate fasteners where they will be inconspicuous. 3. Posts: Fabricate posts to lengths required for mounting method indicated. a. Direct Burial: For permanent sign installation, provide posts 36 inches (900 mm) longer than height of sign to permit direct embedment in concrete foundations. 4. Panels: Form panels to required size and shape. Comply with requirements indicated for design, dimensions, finish, color, and details of construction. a. Coordinate dimensions and attachment methods to produce message panels with closely fitting joints. Align edges and surfaces with one another in the relationship indicated. b. Increase metal thickness or reinforce with concealed stiffeners or backing materials as required to produce surfaces without distortion, buckles, warp, or other surface deformations. c. Continuously weld joints and seams, unless other methods are indicated; grind, fill, and dress welds to produce smooth, flush, exposed surfaces with welds invisible after final finishing.
2.5 DIMENSIONAL LETTERS AND NUMBERS
A. Cast Letters and Numbers: Form individual letters and numbers by casting. Produce characters with smooth, flat faces, sharp corners, and precisely formed lines and profiles, free from pits, scale, sand holes, or other defects. Cast lugs into the back of characters and tap to receive threaded mounting studs. Comply with requirements indicated for finish, style, and size.
1. Metal: Aluminum. 2. Provide letters of size and style as indicated attached to exterior building and monument sign surface as directed by architect. 3. Building Address: Provide letters and/or numbers as required. Attach to exterior wall surface as directed by architect.
2.9 FINISHES
A. Colors and Surface Textures: For exposed sign material that requires selection of materials with integral or applied colors, surface textures or other characteristics related to appearance, provide color matches indicated, or if not indicated, as selected by the Architect from the manufacturer's standards.
B. Metal Finishes: Comply with NAAMM "Metal Finishes Manual" for finish designations and applications recommendations.
C. Aluminum Finishes: Finish designations prefixed by "AA" conform to the system established by the Aluminum Association for designating aluminum finishes.
1. Baked-Enamel Finish: AA-M4xC12C42R1x (Mechanical Finish: Manufacturer's standard, other nondirectional textured; Chemical Finish: Chemical conversion coating, acid chromate-fluoride-phosphate pretreatment; Organic Coating: as
BC&A SIGNS JVWCD PAGE 10425-7 CENTRAL PIPELINE PROJECT specified below). Apply baked enamel in compliance with paint manufacturer's specifications for cleaning, conversion coating, and painting. a. Organic Coating: Thermosetting-modified acrylic enamel primer/topcoat system complying with AAMA 603.8 except with a minimum dry film thickness of 1.5 mils, medium gloss. 1) Color: As selected by the Architect from the manufacturer's standard colors.
PART 3 - EXECUTION
3.1 INSTALLATION
A. General: Locate sign units and accessories where indicated, using mounting methods of the type described and in compliance with the manufacturer's instructions.
1. Install signs level, plumb, and at the height indicated, with sign surfaces free from distortion or other defects in appearance.
B. Exterior Directional and Parking Signs:
1. Excavation: In firm, undisturbed or compacted soil, drill or (using a post-hole digger) hand-excavate holes for each post to the minimum diameter recommended by sign manufacturer, but at least 4 times the largest post cross-section. a. Excavate hole depths approximately 3 inches (75 mm) lower than required post bottom, with bottom of posts set at least 36 inches (900 mm) below finished grade. 2. Setting Posts: Center and align posts in holes 3 inches (75 mm) above bottom of excavation. a. Protect portion of posts aboveground from concrete splatter. Place concrete around posts and vibrate or tamp for consolidation. Check posts for vertical and top alignment and hold in position until concrete has achieved its initial set.
C. Wall-Mounted Panel Signs: Attach panel signs to wall surfaces using the methods indicated below:
1. Provide screws, bolts, and other exposed fastening devices of the same material as the items being fastened. Provide types, gages, and lengths to suit installation conditions. Use theft-proof fasteners where exposed to view.
D. Bracket-Mounted Units: Provide the manufacturer's standard brackets, fittings, and hardware as appropriate for mounting signs that project at right angles from walls and ceilings. Attach brackets and fittings securely to walls or ceilings with concealed fasteners and anchoring devices to comply with manufacturer's directions.
E. Dimensional Letters and Numbers: Mount letters and numbers using standard fastening methods recommended by the manufacturer for letter form, type of mounting, wall construction, and condition of exposure indicated. Provide heavy paper template to establish letter spacing and to locate holes for fasteners.
1. Flush Mounting: Mount letters with backs in contact with the wall surface.
BC&A SIGNS JVWCD PAGE 10425-8 CENTRAL PIPELINE PROJECT
3.2 CLEANING AND PROTECTION
A. After installation, clean soiled sign surfaces according to the manufacturer's instructions. Protect units from damage until acceptance by the Owner.
END OF SECTION
BC&A SIGNS JVWCD PAGE 10425-9 CENTRAL PIPELINE PROJECT
DIVISION 11 EQUIPMENT
SECTION 11000 EQUIPMENT GENERAL PROVISIONS
PART 1 – GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall provide all tools, supplies, materials, equipment, and all labor necessary for the furnishing, construction, installation, testing, and operation of all equipment and appurtenant Work, complete and operable, in accordance with the Contract Documents.
B. The provisions of this Section shall apply to all equipment specified and where referred to, except where otherwise indicated.
1.2 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS
A. Commercial Standards: All equipment, products, and their installation shall be in accordance with the following standards, as applicable, and as indicated in each Section of these Specifications:
1. American Gear Manufacturers Association (AGMA). 2. American Society for Testing and Materials (ASTM). 3. American Public Health Association (APHA). 4. American National Standards Institute (ANSI). 5. American Society of Mechanical Engineers (ASME). 6. American Water Works Association (AWWA). 7. American Society of Heating, Refrigerating, and Air Conditioning Engineers (ASHRAE). 8. Anti-Friction Bearing Manufacturers Association, Inc. (AFBMA). 9. Mechanical Power Transmission Association (MPTA). 10. American Welding Society (AWS). 11. National Fire Protection Association (NFPA). 12. Federal Specifications (FS). 13. National Electrical Manufacturers Association (NEMA). 14. Manufacturer's published recommendations and specifications. 15. General Industry Safety Orders (OSHA). 16. Rubber Manufacturers Association (RMA).
B. The following standards have been referred to in this Section of the Specifications:
ANSI B16.1 Cast Iron Pipe Flanges and Flanged Fittings Class 25, 125, 250, and 800
ANSI B16.5 Pipe Flanges and Flanged Fittings, Steel, Nickel Alloy, and Other Special Alloys
ANSI B46.1 Surface Texture
BC&A EQUIPMENT GENERAL PROVISIONS JVWCD PAGE 11000-1 CENTRAL PIPELINE PROJECT
ANSI S12.6 Method for the Measurement of the Real-Ear Attenuation of Hearing Protectors
ANSI/ASME B1.20.1 General Purpose Pipe Threads (Inch)
ANSI/ASME B31.1 Power Piping
ANSI/AWWA D100 Welded Steel Tanks for Water Storage
AWWA C206 Field Welding of Steel Water Pipe
ASTM A 48 Specification for Gray Iron Castings
ASTM A 108 Specification for Steel Bars, Carbon, Cold-Finished, Standard Quality
1.3 CONTRACTOR SUBMITTALS
A. Shop Drawings: The Contractor shall furnish complete shop drawings for all equipment specified in the various Sections, together with all piping, valves, and controls for review by the Engineer in accordance with Section 01300 - Contractor Submittals.
B. Tools: The Contractor shall supply one complete set of special wrenches and other special tools necessary for the assembly, adjustment, and dismantling of the equipment. All tools shall be of best quality hardened steel forgings with bright, finish wrench heads shall have work faces dressed to fit applicable nuts and bolts. All tools shall be suitable for professional work and manufactured by a recognized supplier of professional tools such as Snap On, Crescent, Stanley, or equal. The set of tools shall be neatly mounted in a labeled tool box of suitable design provided with a hinged cover and separate from other manufacturer provided parts. For each microprocessor-based equipment system requiring a handheld device for configuration, furnish one handheld device.
C. Spare Parts: The Contractor shall obtain and submit from the manufacturer a list of suggested spare parts for each piece of equipment. After approval, Contractor shall furnish such spare parts suitably packaged, identified with the equipment number, and labeled. Contractor shall also furnish the name, address, and telephone number of the nearest distributor for each piece of equipment. All spare parts are intended for use by the OWNER only, after expiration of the guaranty period.
D. Torsional Analysis: The Contractor shall submit to the Engineer a torsional and lateral vibration analysis of the following equipment, in accordance with Section 01300 - Contractor Submittals. The analysis must be performed by a specialist experienced in this type of Work and approved by the Engineer.
1. All engine drives. 2. All blowers and compressors with drives of 100 horsepower and over. 3. All vertical pumps with universal joints and extended shafts. 4. All other equipment where indicated.
BC&A EQUIPMENT GENERAL PROVISIONS JVWCD PAGE 11000-2 CENTRAL PIPELINE PROJECT
The torsional natural frequency of the drive train must be avoided by plus and minus 25 percent by any exciting frequency of the equipment, throughout the entire operating range.
E. Vibration Analysis: In the bid price the Contractor shall include at least two site visits of the above mentioned specialist, during construction and testing of the equipment, to analyze and measure the amount of equipment vibration and make his written recommendation for keeping the vibration at a safe limit.
F. Operation and Maintenance Manuals: Submit in accordance with Section 01300 – Contractor Submittals prior to equipment start up and training.
1.4 QUALITY ASSURANCE
A. Inspection, Startup, and Field Adjustment: The Contractor shall demonstrate that all equipment meets the specified performance requirements. Contractor shall provide the services of an experienced, competent, and authorized service representative of the manufacturer of each item of major equipment who shall visit the site to perform the following tasks:
1. Assist the Contractor in the installation of the equipment. 2. To inspect, check, adjust if necessary and approve the equipment installation. 3. To start-up and field-test the equipment for proper operation, efficiency, and capacity. 4. To perform necessary field adjustments during the test period until the equipment installation and operation are satisfactory to the Engineer. 5. To instruct the Owner’s personnel in the operation and maintenance of the equipment. Instruction shall include step-by-step trouble shooting procedures with all necessary test equipment.
B. Costs: The costs of all inspection, startup, testing, adjustment, and instruction Work performed by said factory-trained representatives shall be borne by the Contractor. The Owner will pay for costs of power and water where applicable. When available, the Owner’s operating personnel will provide assistance in the field testing.
C. Public Inspection: It shall be the responsibility of the Contractor to inform the local authorities, such as building and plumbing inspectors, Fire Marshall, OSHA inspectors, and others, to witness all required tests for piping, plumbing, fire protection systems, pressure vessels, and safety systems to obtain all required permits and certificates, and pay all fees.
D. Tolerances: Tolerances and clearances shall be as shown on the shop drawings and shall be closely adhered to. Machine Work shall in all cases be of high-grade workmanship and finish, with due consideration to the special nature or function of the parts. Members without milled ends and which are to be framed to other steel parts of the structure may have a variation in the detailed length of not greater than 1/16-inch for members 30 feet or less in length, and not greater than 1/8-inch for members over 30 feet in length.
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E. Machine Finish: The type of finish shall be the most suitable for the application and shall be shown in micro-inches in accordance with ANSI B46.1. The following finishes shall be used:
1. Surface roughness not greater than 63 micro-inches shall be required for all surfaces in sliding contact. 2. Surface roughness not greater than 250 micro-inches shall be required for surfaces in contact where a tight joint is not required. 3. Rough finish not greater than 500 micro-inches shall be required for other machined surfaces. 4. Contact surfaces of shafts and stems which pass through stuffing boxes and contact surfaces of bearings shall be finished to not greater than 32 micro- inches.
F. Manufacturer's Experience: Unless otherwise directed by the ENGINEER, all equipment furnished shall have a record of at least 5 years of successful, trouble free operation in similar applications, from the same manufacturer.
PART 2 – PRODUCTS
2.1 GENERAL REQUIREMENTS
A. High Noise Level Location: The Contractor shall provide one personal hearing protection station, as indicated herein, at each high noise level location. Said locations are defined as follows:
1. Outdoor Location: Any single equipment item or any group of equipment items that produce noise exceeding OSHA noise level requirements for a 2-hour exposure. Where such equipment is separated by a distance of more than 20 feet, measured between edges of footings, each group of equipment shall be provided with a separate hearing protection station. 2. Indoor Location a. Any single equipment item, or any group of equipment items, located within a single room not normally occupied, that produces noise exceeding OSHA noise level requirements for a 2-hour exposure. b. Any single equipment item, or any group of equipment items, located within a single room normally occupied by workers that produces noise exceeding OSHA noise level requirements for an 8-hour exposure. 3. Personal Hearing Protection: The Contractor shall supply, in their original unopened packaging, three pairs of high attenuation hearing protectors. The ear protectors shall be capable of meeting the requirements of ANSI S12.6 and shall produce a noise level reduction of 25 dBA at a frequency of 500 Hz. The hearing protectors shall have fluid filled ear cushions and an adjustable, padded headband. The protectors shall be stored in a weatherproof, labeled, steel cabinet, furnished by the Contractor and mounted in an approved location near the noise protection station.
B. Service Factors: Service factors shall be applied in the selection or design of mechanical power transmission components. Unless otherwise indicated, the following load classifications shall apply in determining service factors:
BC&A EQUIPMENT GENERAL PROVISIONS JVWCD PAGE 11000-4 CENTRAL PIPELINE PROJECT
Type of Equipment Load Classification
Blower: Centrifugal or vane Uniform Lobe Moderate Shock
Reciprocating Air Compressor: Multi-Cylinder Moderate Shock Single-Cylinder Heavy Shock
Pump: Centrifugal or Rotary Uniform Reciprocating Moderate Shock
Mixer: Constant Density Uniform Variable Density Moderate Shock
Crane or Hoist Moderate Shock
C. For service factors of electric motors, see Section 16460 - Electric Motors. Where load classifications are not indicated, best modern practice shall be used.
D. Welding: Unless otherwise indicated, all welding shall conform to the following:
1. Latest revision of ANSI/AWWA D100. 2. Latest revision of AWWA C206. 3. All composite fabricated steel assemblies which are to be erected or installed inside a hydraulic structure, including any fixed or movable structural components of mechanical equipment, shall have continuous seal welds to prevent entrance of air or moisture. 4. All welding shall be by the metal-arc method or gas-shielded arc method as described in the American Welding Society's "Welding Handbook" as supplemented by other pertinent standards of the AWS. Qualification of welders shall be in accordance with the AWS Standards governing same. 5. In assembly and during welding, the component parts shall be adequately clamped, supported, and restrained to minimize distortion and for control of dimensions. Weld reinforcement shall be as specified by the AWS code. Upon completion of welding, all weld splatter, flux, slag, and burrs left by attachments shall be removed. Welds shall be repaired to produce a workmanlike appearance, with uniform weld contours and dimensions. All sharp corners of material which is to be painted or coated shall be ground to a minimum of 1/32- inch on the flat.
E. Protective Coating: All equipment shall be painted or coated in accordance with Section 09900 – Coatings and Painting, unless otherwise indicated. Nonferrous metal and corrosion-resisting steel surfaces shall be coated with grease or lubricating oil. Coated surfaces shall be protected from abrasion or other damage during handling, testing, storing, assembly, and shipping.
BC&A EQUIPMENT GENERAL PROVISIONS JVWCD PAGE 11000-5 CENTRAL PIPELINE PROJECT
F. Protection of Equipment: All equipment shall be boxed, crated, or otherwise protected from damage and moisture during shipment, handling, and storage by methods recommended by the manufacturer. All equipment shall be protected from exposure to corrosive fumes and shall be kept thoroughly dry at all times. Pumps, motors, drives, electrical equipment, and other equipment having anti-friction or sleeve bearings shall be stored in weathertight storage facilities prior to installation. For extended storage periods, plastic equipment wrappers should be avoided, to prevent accumulation of condensate in gears and bearings.
G. Identification of Equipment Items: Each item of equipment shipped shall have a legible identifying mark corresponding to the equipment number indicated for the particular item.
H. Vibration Level: All equipment subject to vibration shall be provided with restrained spring-type vibration isolators or pads per manufacturer's written recommendations.
I. Shop Fabrication: Shop fabrication shall be performed in accordance with the Contract Documents and the Engineer-approved shop drawings.
2.2 EQUIPMENT SUPPORTS AND FOUNDATIONS
A. Equipment Supports: All equipment supports, anchors, and restrainers shall be adequately designed for static, dynamic, wind, and seismic loads. The design horizontal seismic force shall be the greater of: that noted in the general structural notes or as required by the governing building code, or 10 percent of gravity. Submitted design calculations for equipment supports must bear the signature and seal of an Engineer registered in the state of Utah.
B. Equipment Foundations: Equipment foundations shall be as per manufacturer's written recommendations. All mechanical equipment, tanks, and control cabinets shall be mounted on concrete bases as shown in the project standard structural details.
C. Shop Drawings: Shop drawings shall be submitted to the Engineer for review in accordance with the requirements of Section 01300 – Contractor Submittals. Shop drawings will be considered incomplete unless clear, concise calculations are presented showing equipment anchorage forces and the capacities of the anchorage elements provided by the Contractor.
2.3 PIPE HANGERS, SUPPORTS, AND GUIDES
A. All pipe connections to equipment shall be supported, anchored, and guided to avoid stresses and loads on equipment flanges and equipment. Supports and hangers shall be in accordance with the requirements of Section 15006 - Pipe Supports.
2.4 FLANGES AND PIPE THREADS
A. All flanges on equipment and appurtenances provided under this Section shall conform to ANSI B16.1, Class 125; or B16.5, Class 150, unless otherwise indicated. All pipe threads shall be in accordance with ANSI/ASME B1.20.1, and with requirements of Section 15000 - Piping, General.
BC&A EQUIPMENT GENERAL PROVISIONS JVWCD PAGE 11000-6 CENTRAL PIPELINE PROJECT
2.5 COUPLINGS
A. Flexible couplings shall be provided between the driver and the driven equipment to accommodate slight angular misalignment, parallel misalignment, end float, and to cushion shock loads. Where required for vertical shafts, 3-piece spacer couplings or universal type couplings for extended shafts shall be installed.
B. The CONTRACTOR shall coordinate with the equipment manufacturer to select and/or recommend the size and type of coupling required to suit each specific application.
C. Taper-lock bushings may be used to provide for easy installation and removal on shafts of various diameters.
D. Where universal type couplings are shown, they shall be of the needle bearing type construction, equipped with commercial type grease fittings.
2.6 SHAFTING
A. General: All shafting shall be continuous between bearings and shall be sized to transmit the power required. Keyways shall be accurately cut in line. Shafting shall not be turned down at the ends to accommodate bearings or sprockets whose bore is less than the diameter of the shaft. All shafts shall rotate in the end bearings and shall be turned and polished, straight, and true.
B. Materials: Shafting materials shall be appropriate for the type of service and torque transmitted. Environmental elements such as corrosive gases, moisture, and fluids shall be taken into consideration. Materials shall be as indicated unless furnished as part of an equipment assembly.
1. Low carbon cold-rolled steel shafting shall conform to ASTM A 108, Grade 1018. 2. Medium carbon cold-rolled shafting shall conform to ASTM A 108, Grade 1045. 3. Corrosion-resistant shafting shall be stainless steel or Monel, whichever is most suitable for the intended service.
C. Differential Settlement: Where differential settlement between the driver and the driven equipment may be expected, a shaft of sufficient length with two sets of universal type couplings shall be provided.
2.7 BEARINGS
A. General: Bearings shall conform to the standards of the AFBMA.
B. To assure satisfactory bearing application, fitting practice, mounting, lubrication, sealing, static rating, housing strength, and other important factors shall be considered in bearing selection.
C. All lubricatable type bearings shall be equipped with a hydraulic grease fitting in an accessible location and shall have sufficient grease capacity in the bearing chamber.
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D. All lubricated-for-life or sealed bearings shall be factory-lubricated with the manufacturer's recommended grease to insure maximum bearing life and best performance.
E. Bearing Life: Except where otherwise indicated, all bearings shall have a minimum L-10 life expectancy of 5 years or 20,000 hours, whichever occurs first. Where indicated, bearings shall have a minimum rated L-10 life expectancy corresponding to the type of service, as follows:
Type of Service Design Life (years)* L-10 Design Life (hours)* 8-hour shift 10 20,000 16-hour shift 10 40,000 Continuous 10 60,000 * = Design Life in years or L-10 Design Life in hours, whichever occurs first
F. Bearing housings shall be of cast iron or steel and bearing mounting arrangement shall be as indicated, or as recommended in the published standards of the manufacturer if not indicated. Split-type housings may be used to facilitate installation, inspection, and disassembly.
G. Sleeve-type bearings shall have a Babbitt or bronze liner.
2.8 GEARS AND GEAR DRIVES
A. Unless otherwise indicated, gears shall be of the helical or spiral-bevel type, designed and manufactured in accordance with AGMA Standards, with a minimum service factor of 1.7, a minimum L-10 bearing life of 60,000 hours and a minimum efficiency of 94 percent. Worm gears shall not be used, unless specifically approved by the Engineer.
B. All gear speed reducers or increases shall be of the enclosed type, oil- or grease- lubricated and fully sealed, with a breather to allow air to escape but keep dust and dirt out. The casing shall be of cast iron or heavy duty steel construction with lifting lugs and an inspection cover for each gear train. An oil level sight glass and an oil flow indicator shall be provided, arranged for easy reading.
C. Gears and gear drives as part of an equipment assembly shall be shipped fully assembled for field installation.
D. Material selections shall be left to the discretion of the manufacturer, provided the above AGMA values are met. Input and output shafts shall be adequately designed for the service and load requirements. Gears shall be computer-matched for minimum tolerance variation. The output shaft shall have two positive seals to prevent oil leakage.
E. Oil level and drain location relative to the mounting arrangement shall be easily accessible. Oil coolers or heat exchangers with all required appurtenances shall be furnished when necessary.
F. Where gear drive input or output shafts have to connect to couplings or sprockets supplied by others, the Contractor shall have the gear drive manufacturer supply matching key taped to the shaft for shipment.
BC&A EQUIPMENT GENERAL PROVISIONS JVWCD PAGE 11000-8 CENTRAL PIPELINE PROJECT
2.9 DRIVE CHAINS
A. Power drive chains shall be commercial type roller chains and meet ANSI Standards.
B. A chain take-up or tightener shall be provided in every chain drive arrangement to provide easy adjustment.
C. A minimum of one connecting or coupler link shall be provided with each length of roller chain.
D. Chain and attachments shall be of the manufacturer's best standard material and suitable for the process fluid.
2.10 SPROCKETS
A. General: Sprockets shall be used in conjunction with all chain drives and chain-type material handling equipment.
B. Materials: Unless otherwise indicated, materials shall be as follows:
1. Sprockets with 25 teeth or less, normally used as a driver, shall be made of medium carbon steel in the 0.40 to 0.45 percent carbon range. 2. Type A and B sprockets with 26 teeth or more, normally used as driven sprockets, shall be made of minimum 0.20 percent carbon steel. 3. Large diameter sprockets with Type C hub shall be made of cast iron conforming to ASTM A 48, Class 30.
C. All sprockets shall be accurately machined to ANSI Standards. Sprockets shall have deep hardness penetration in tooth sections.
D. Finish bored sprockets shall be furnished complete with keyseat and set screws.
E. To facilitate installation and disassembly, sprockets shall be of the split type or shall be furnished with taper-lock bushings as required.
F. Idler sprockets shall be furnished with brass or Babbitt bushings, complete with oil hole and axial or circumferential grooving. Steel collars with set screws may be provided in both sides of the hub.
2.11 V-BELT DRIVES
A. V-belts and sheaves shall be of the best commercial grade and shall conform to ANSI, MPTA, and RMA Standards.
B. Unless otherwise indicated, sheaves shall be machined from the finest quality gray cast iron.
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C. All sheaves shall be statically balanced. In some applications where vibration is a problem, sheaves shall be dynamically balanced. Sheaves operating at belt speeds exceeding 6,500 fpm may be required to be of special materials and construction.
D. To facilitate installation and disassembly, sheaves shall be furnished complete with taper-lock or QD bushings as required.
E. Finish bored sheaves shall be furnished complete with keyseat and set screws.
F. Sliding motor bases shall be provided to adjust the tension of V-belts.
2.12 DRIVE GUARDS
A. All power transmission, prime movers, machines, shaft extensions, and moving machine parts shall be guarded to conform to the OSHA Safety and Health Standards (29CFR1910). The guards shall be constructed of minimum 10 gauge expanded, flattened steel with smooth edges and corners, galvanized after fabrication and securely fastened. Where required for lubrication or maintenance, guards shall have hinged and latched access doors.
2.13 FLEXIBLE CONNECTORS
A. General: Flexible connectors shall be installed in all piping connections to engines, blowers, compressors, and other vibrating equipment and in piping systems in accordance with Section 15000 - Piping, General and project mechanical details.
2.14 INSULATING CONNECTIONS
A. General: Insulating bushings, unions, couplings, or flanges, as appropriate, shall be used in accordance with the requirements of the Section 15000 - Piping, General and project mechanical details.
2.15 GASKETS AND PACKINGS
A. Gaskets shall be in accordance with the requirements of Section 15000 - Piping, General.
B. Packing around valve stems and reciprocating shafts shall be of compressible material, compatible with the fluid being used. Chevron-type "V" packing shall be Garlock No. 432, John Crane "Everseal," or equal.
C. Packing around rotating shafts (other than valve stems) shall be "O"-rings, stuffing boxes, or mechanical seals, as recommended by the manufacturer and approved by the ENGINEER, in accordance with Section 11100 - Pumps, General.
2.16 NAMEPLATES
A. Equipment nameplates of stainless steel shall be engraved or stamped and fastened to the equipment in an accessible location with No. 4 or larger oval head stainless steel screws or drive pins. Nameplates shall contain the manufacturer's name, model, serial
BC&A EQUIPMENT GENERAL PROVISIONS JVWCD PAGE 11000-10 CENTRAL PIPELINE PROJECT
number, size, characteristics, and appropriate data describing the machine performance ratings.
2.17 SAFETY REQUIREMENTS
A. Where Work areas are located within a flammable or toxic gas environment, suitable gas detection, ventilating, and oxygen deficiency equipment shall be provided. Workers shall be equipped with approved breathing apparatus.
2.18 OVERLOAD PROTECTION
A. General: Unless otherwise indicated in individual equipment Sections, all equipment drives incorporating overload protection shall be provided with an overload protection device.
B. Mechanical Torque Monitoring System: The overload protection shall be a mechanical device to provide for reliable protection in the event of excessive overload. It shall be a ball detent type designed for long term repeatability and life. It shall be infinitely adjustable by a single adjusting nut. Once set it shall be tamperproof, and incorporate a torque monitoring and control system. It shall activate an alarm set for 85 percent, and a motor cutout switch set for 100 percent of maximum continuous running torque. A visual torque indication shall be provided and oriented so that it may be read from the walkway. The dial shall be calibrated from 0 to 100 percent of maximum continuous running torque. The design of the torque limiter should initiate the mechanical disengagement of the drive upon overload. Each unit shall be suitable for outdoor/corrosive environments with a protective finish, corrosion inhibiting lubricants and a stainless steel cover.
C. Electronic Torque Monitoring System:
1. As an alternative to the mechanical system, the overload protection may be an Electronic Torque Monitoring Control System capable of displaying torque, rpm's, one level of overload, and two levels of overload of the drive system. It shall incorporate a time-delay for start-up and a voltage monitoring and compensation circuit for up to +15 percent variation. 2. The overload device shall be housed in an enclosure with NEMA rating in accordance with the area designations of Section 16050 - Electrical General Provisions. A visual torque dial shall be provided and oriented so that it can be easily read from the walkway. 3. The torque monitoring system shall be calibrated to: alarm and shut down the system in the event the torque drops to 50 percent of normal running; alarm at 85 percent of maximum continuous running torque and shut down the motor at maximum continuous running torque of the equipment. The system shall be calibrated at the factory of the equipment manufacturer and it shall be capable of monitoring twice the maximum continuous running torque of the equipment.
D. Manufacturers, or Equal
1. American Autogard Corporation; 2. Ferguson Machine Company.
BC&A EQUIPMENT GENERAL PROVISIONS JVWCD PAGE 11000-11 CENTRAL PIPELINE PROJECT
PART 3 – EXECUTION
3.1 COUPLINGS
A. The Contractor shall coordinate with the equipment manufacturer to select and/or recommend the size and type of coupling required to suit each specific application; installation shall be per equipment manufacturer's printed recommendations.
3.2 INSULATING CONNECTIONS
A. All insulating connections shall be installed in accordance with the manufacturer's printed instructions.
3.3 PIPE HANGERS, SUPPORTS, AND GUIDES
A. Hangers, supports, seismic bracing and guides shall be spaced in accordance with ANSI/ASME B.31.1 standard, and with tables in Section 15006 - Pipe Supports.
3.4 PACKAGED EQUIPMENT
A. When any system is furnished as pre-packaged equipment, the Contractor shall coordinate with subcontractors all necessary space and structural requirements, clearances, utility connections, signals, and outputs.
B. If the packaged system has any additional features (for example, safety interlocks), other than indicated, the Contractor shall coordinate such features with the Engineer and furnish all material and labor necessary for a complete installation as required by the manufacturer, at no additional cost to the Owner.
END OF SECTION
BC&A EQUIPMENT GENERAL PROVISIONS JVWCD PAGE 11000-12 CENTRAL PIPELINE PROJECT SECTION 11100 PUMPS, GENERAL
PART 1 – GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall provide all pumps and pumping appurtenances, complete and operable, in accordance with the Contract Documents.
B. The provisions of this Section shall apply to all pumps and pumping equipment except where otherwise indicated in the Contract Documents.
C. Unit Responsibility: A single manufacturer shall be made responsible for furnishing the Work and for coordination of design, assembly, testing, and installation of the Work of each pump Section; however, the Contractor shall be responsible to the Owner for compliance with the requirements of each pump Section. Unless otherwise indicated, the single Manufacturer shall be the Manufacturer of the pump.
D. Single Manufacturer: Where two or more pump systems of the same type or size are required, the pumps shall all be produced by the same Manufacturer.
1.2 CONTRACTOR SUBMITTALS
A. General: Submittals shall be furnished in accordance with Section 01300 - Contractor Submittals.
B. Shop Drawings: Shop drawings shall contain the following information:
1. Pump name, identification number, and specification Section number. 2. Performance data curves showing head, capacity, horsepower demand, NPSH required, and pump efficiency over the entire operating range of the pump. The equipment Manufacturer shall indicate separately the head, capacity, horsepower demand, overall efficiency, and minimum submergence required at the design flow conditions and the maximum and minimum flow conditions. A family of performance curves at intervals of 100 rpm from minimum speed to maximum speed shall be provided for each centrifugal pump equipped with a variable frequency drive. 3. The Contractor shall require the Manufacturer to indicate on the performance curves the limits recommended for stable operation without surge, without cavitation, and without vibration (except vibration within specified allowable limits). The stable operating range shall be as wide as possible based on actual hydraulic and mechanical measurements taken during the factory performance tests of the pumps. 4. Assembly and installation drawings including shaft size, seal, coupling, bearings, anchor bolt plan, part nomenclature, material list, outline dimensions, and shipping weights. 5. Data, in accordance with Section 16460 - Electric Motors, for the electric motor proposed for each pump.
BC&A PUMPS, GENERAL JVWCD PAGE 11100-1 CENTRAL PIPELINE PROJECT 6. Elevation of proposed Local Control Panel showing panel-mounted devices, details of enclosure type, single line diagram of power distribution, and current draw of panel, and list of all terminals required to receive inputs or to transmit outputs from the Local Control Panel. 7. Wiring diagram of field connections with identification of terminations between Local Control Panels, junction terminal boxes, and equipment items. 8. Complete electrical schematic diagram.
C. Operation and Maintenance Manual: The Manual shall contain the required information for each pump Section.
D. Spare Parts List: A Spare Parts List shall contain the required information for each pump Section.
E. Factory Test Data: Signed, dated, and certified factory test data for each pump system which requires factory testing, submitted before shipment of equipment.
F. Certifications
1. Manufacturer's certification of proper installation. 2. Contractor's certification of satisfactory field testing.
1.3 QUALITY ASSURANCE
A. Factory Testing: The following tests shall be conducted on each indicated pump system:
1. Motors: All motors of sizes 100 hp and larger shall be assembled, tested, and certified at the motor factory and the working clearances checked to insure that all parts are properly fitted. The tests shall be in accordance with ANSI/IEEE 112 - Test Procedure for Polyphase Induction Motors and Generators, and ANSI/IEEE 115 - Test Procedure for Synchronous Machines, including heat run and efficiency tests. All computations shall be recorded and certified and dated copies of the test results shall be furnished. 2. Pump Systems: All centrifugal pump systems 100 hp and larger shall be tested at the pump factory in accordance with the Test Code for Centrifugal Pumps of the Standards of the Hydraulic Institute, Inc. Tests shall be performed using the complete pump system to be furnished, including the motor. 3. For motors smaller than 100 hp, the Manufacturer's certified test motor shall be acceptable. Testing of prototype models will not be acceptable. The following minimum test data shall be submitted: a. Hydrostatic test data b. A minimum of five hydraulic test readings between shutoff head and 25 percent beyond the maximum indicated capacity, recorded on data sheets as defined by the Hydraulic Institute. c. Pump curves showing head, flow, bhp, efficiency, and NPSH requirements. d. Certification that the pump horsepower demand did not exceed the rated motor hp beyond the 1.0 service rating at any point on the curve.
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4. Factory Witnessed Tests: All pumps, variable speed drives, and motors, 150 hp and larger shall be factory-tested as complete assembled systems and may be witnessed by the Owner and Engineer. The use of one of each type project motor and variable frequency drive for testing all pumps shall be acceptable. The Contractor shall give the Engineer a minimum of 4 weeks notification prior to the test. All costs for Owner and Engineer expenses shall be borne by the Contractor and shall be included in the bid price. Such costs shall include travel and subsistence for two people excluding salaries. Test results shall be submitted to the Engineer and no equipment shall be shipped until the test data have been approved by the Engineer.
B. Warranty: Unless otherwise specified, each pump shall be supplied with manufacturer’s standard warranty for one (1) year from project substantial completion.
PART 2 – PRODUCTS
2.1 GENERAL
A. Compliance with the requirements of the individual pump Sections may necessitate modifications to the Manufacturer's standard equipment.
B. Performance Curves: All centrifugal pumps shall have a continuously rising curve. In no case shall the required horsepower at any point on the performance curve exceed the rated horsepower of the motor or engine, or encroach on the service factor.
C. No cavitation shall be allowed in pumps operating within the stable operating range for the specified operating conditions. For the purposes of this provision, cavitation shall be recognized and accepted as being present in a pumping unit if cavitation noise can be perceived either by the human ear or by acoustic instruments or devices. The presence or absence of cavitation noise shall be verified by the Owner during both the factory performance tests of the pumps and during operation of the pumps up to the end of the warranty period. To assist in revealing potential cavititation during the factory performance tests, in addition to all other required tests, the Manufacturer shall force the pumps to operate at the specified minimum net positive suction head available for each of the following conditions: minimum flow rate, design flow rate and head, and maximum flow rate.
D. All components of each pump system provided under the pump Sections shall be entirely compatible. Each unit of pumping equipment shall incorporate all basic mechanisms, couplings, electric motors, variable frequency controls if required, necessary mountings, and appurtenances.
BC&A PUMPS, GENERAL JVWCD PAGE 11100-3 CENTRAL PIPELINE PROJECT 2.2 MATERIALS OF CONSTRUCTION
A. All materials shall be suitable for the intended application; materials not specified shall be high-grade, standard commercial quality, free from all defects and imperfection that might affect the serviceability of the product for the purpose for which it is intended, and shall conform to the following requirements:
1. Cast iron pump casings and bowls shall be of austenitic ductile iron, conforming to ASTM A 439 - Specification for Austenitic Ductile Iron Castings, or equal. 2. Bronze pump impellers shall conform to ASTM B 62 - Specification for Composition Bronze or Ounce Metal Castings, or B 584 - Specification for Copper Alloy Sand Castings for General Applications, where dezincification does not exist. 3. Stainless steel pump shafts shall be Type 416 or 316. Miscellaneous stainless steel parts shall be of Type 316. 4. All anchor bolts, nuts, and washers that are not buried or submerged shall be hot-dip galvanized, unless otherwise specified in individual pump Sections. Buried or submerged bolts, nuts, and washers shall be stainless steel in accordance with Section 05500 - Miscellaneous Metalwork.
2.3 PUMP COMPONENTS
A. Flanges: Suction and discharge flanges shall conform to ANSI/ASME B16.1 - Cast Iron Pipe Flanges and Flanged Fittings, Class 25, 125, 250, and 800 or B16.5 - Pipe Flanges and Flanged Fittings Dimensions.
B. Lubrication: Vertical pump shafts of clean water pumps shall be product water- lubricated, unless otherwise specified. Deep-well pumps and pumps with dry barrels shall have water- or oil-lubricated bearings and seals and enclosed lineshafts. Pumps for other process fluids shall be lubricated as indicated.
C. Handholes: Handholes on pump casings shall be shaped to follow the contours of the casing to avoid any obstructions in the water passage.
D. Vortex Suppressors: Vertical pumps with marginal submergence shall be provided with vortex suppressors.
E. Drains: All gland seals, air valves, cooling water drains, and drains from variable frequency drive equipment shall be piped to the nearest floor sink, or drain, with galvanized steel pipe or copper tube, properly supported with brackets.
G. Grease Lubrication: For all vertical propeller, mixed-flow, and turbine pumps, other than deep well pumps, of bowl sizes 10-inches and larger, the Contractor shall provide a stainless steel tube attached to the column for grease lubrication of the bottom bearing.
BC&A PUMPS, GENERAL JVWCD PAGE 11100-4 CENTRAL PIPELINE PROJECT H. Stuffing Boxes: Where stuffing boxes are indicated for the pump seal, they shall be of the best quality, using the Manufacturer's suggested materials best suited for the specific application. For drainage and liquids containing sediments, the seals shall be fresh- water flushed, using lantern rings.
1. Unless otherwise specified, the packing material shall be interlaced Teflon braiding, containing 50 percent ultrafine graphite impregnation to satisfy the following: a. Shaft speeds - up to 2500 rpm b. Temperature - up to 500 degrees F c. pH range - 0 to 14. 2. If fresh water is not available, the seal shall be flushed with product water cleaned by a solids separator as manufactured by John Crane Co., Lakos (Claude Laval Corp.), or equal.
I. Mechanical Seals: Mechanical seals shall be fresh water-flushed unless indicated otherwise; in which case product water cleaned by a solids separator as above shall be used. Mechanical seals shall be as manufactured by the following, or equal:
Type Manufacturer Wastewater Pumps Double seals: John Crane Type L Double; Borg-Warner Type L Double; Chesterton Abrasives, Grit, or Double seals: Lime Slurry Pumps John Crane Type I (hard faces); Borg-Warner Type L (hard faces); Chesterton Chemicals or Single seals: Corrosive Liquid John Crane Type 8-1, 9; Pumps Borg-Warner Type Q, QB; Chesterton Water Pumps Single seals: Hot and Cold John Crane, Type I, 21; Borg-Warner Type L; Chesterton
J. Where indicated, a buffer fluid must be circulated a minimum 20 psi above discharge pressure, or as required by the Manufacturer, in order to maintain reliable seal performance.
K. Mechanical seals for all services other than chemicals and corrosives shall be equipped with nonclogging, single coil springs and nonsliding, internal, secondary elastomers. Metal parts shall be Type 316 stainless steel, Alloy 20, or Hastelloy B or C.
2.4 PUMP APPURTENANCES
A. Nameplates: Each pump shall be equipped with a stainless steel nameplate indicating serial numbers, rated head and flow, impeller size, pump speed, and Manufacturer's
BC&A PUMPS, GENERAL JVWCD PAGE 11100-5 CENTRAL PIPELINE PROJECT name and model number. Dimension and flow information shall be in metric units, followed by English units in parentheses.
B. Solenoid Valves: The pump Manufacturer shall provide solenoid valves on the water or oil lubrication lines and on all cooling water lines. Solenoid valve electrical ratings shall be compatible with the motor control voltage.
C. Gauges: all pumps (except sample pumps, sump pumps, and hot water circulating pumps) shall be equipped with pressure gauges installed at pump discharge lines. Pump suction lines shall be provided with compound gauges. Gauges shall be located in a representative location, where not subject to shock or vibrations, in order to achieve true and accurate readings.
1. Where subject to shock or vibrations, the gauges shall be wall-mounted or attached to galvanized channel floor stands and connected by means of flexible connectors. 2. Pressure and compound gauges shall be provided in accordance with Section 17131 – Pressure Gauges.
PART 3 – EXECUTION
3.1 SERVICES OF MANUFACTURER
A. Inspection, Startup, and Field Adjustment: Where required by the individual pump Sections, an authorized service representative of the Manufacturer shall visit the site for the number of days indicated in those Sections to witness the following and to certify in writing that the equipment and controls have been properly installed, aligned, lubricated, adjusted, and readied for operation.
1. Installation of the equipment. 2. Inspection, checking, and adjusting the equipment. 3. Startup and field testing for proper operation. 4. Performing field adjustments to ensure that the equipment installation and operation comply with the specified requirements.
B. Instruction of the Owner’s Personnel
1. Where required by the individual pump Sections, an authorized training representative of the Manufacturer shall visit the site for the number of days indicated in those Sections to instruct the Owner’s personnel in the operation and maintenance of the equipment, including step-by-step troubleshooting with necessary test equipment. Instruction shall be specific to the models of equipment provided. 2. The representative shall have at least two year's experience in training. A resume for the representative shall be submitted. 3. Training shall be scheduled a minimum of three weeks in advance of the first session. 4. Proposed training material and a detailed outline of each lesson shall be submitted for review. Comments shall be incorporated into the material.
BC&A PUMPS, GENERAL JVWCD PAGE 11100-6 CENTRAL PIPELINE PROJECT 3. The training materials shall remain with the trainees. 4. The Owner may videotape the training for later use with the Owner personnel.
3.2 INSTALLATION
A. General: Pumping equipment shall be installed in accordance with the Manufacturer's written recommendations.
B. Alignment: All equipment shall be field tested to verify proper alignment, operation as specified, and freedom from binding, scraping, vibration, shaft runout, or other defects. Pump drive shafts shall be measured just prior to assembly to ensure correct alignment without forcing. Equipment shall be secure in position and neat in appearance.
C. Lubricants: The Contractor shall provide the necessary oil and grease for start-up and testing operations.
3.3 PROTECTIVE COATING
A. Materials and equipment shall be coated as required in Section 09900 – Coatings and Painting.
3.4 FIELD TESTS
A. Where required by the individual pump Sections, each pump system shall be field tested after installation to demonstrate satisfactory operation without excessive noise, vibration, cavitation, or overheating of bearings.
B. The following field testing shall be conducted:
1. Startup, check, and operate the pump system over its entire speed range. Vibration shall be within the amplitude limits recommended by the Hydraulic Institute Standards at a minimum of four pumping conditions defined by the Engineer. 2. Obtain concurrent readings of motor voltage, amperage, pump suction head, and pump discharge head for at least four pumping conditions at each pump rotational speed. Check each power lead to the motor for proper current balance. 3. Determine bearing temperatures by contact type thermometer. A run time of at least 20 minutes shall precede this test, unless insufficient liquid volume is available. 4. Electrical and instrumentation tests shall conform to the requirements of the Sections under which that equipment is indicated.
C. Field testing shall be witnessed by the Engineer. The Contractor shall furnish the Engineer a written 5 days advance notice of field testing.
D. In the event any pumping system fails to meet the test requirements, it shall be modified and retested as above until it satisfies the requirements at no additional cost to the owner.
BC&A PUMPS, GENERAL JVWCD PAGE 11100-7 CENTRAL PIPELINE PROJECT E. After each pumping system has satisfied the requirements, the Contractor shall certify in writing that it has been satisfactorily tested and that all final adjustments have been made. Certification shall include the date of the field tests, a listing of all persons present during the tests, and the test data.
F. The Contractor shall bear all costs of field tests, including related services of the Manufacturer's representative, except for power and water which the Owner will bear. If available, the Owner’s operating personnel will provide assistance in field testing.
END OF SECTION
BC&A PUMPS, GENERAL JVWCD PAGE 11100-8 CENTRAL PIPELINE PROJECT SECTION 11111 ANSI HORIZONTAL END SUCTION MAGNETIC DRIVE PUMPS
PART 1 GENERAL
1.1 THE REQUIREMENT
A. The CONTRACTOR shall provide ANSI horizontal frame mounted end suction magnetic drive pumps, with horizontal electric motors and all appurtenant work, complete and operable, in accordance with the Contract Documents.
B. The requirements of Section 11100 – Pumps, General apply to this Section.
C. The Supplier shall examine the Site conditions, intended application, and operation of the pump system and recommend the pump that will best satisfy the indicated requirements.
1.2 REFERENCES
A. American Bearing Manufacturers Association (ABMA): 1. 9 - Load Ratings and Fatigue Life for Ball Bearings. 2. 11 - Load Ratings and Fatigue Life for Roller Bearings.
B. American National Standards Institute/American Society of Mechanical Engineers (ANSI/ASME): 1. B16.1 - Cast Iron Pipe Flanges and Flanged Fittings, Class 25, 125, 250, and 800. 2. B16.5 - Pipe Flanges and Flanged Fittings. 3. B73.1 - Specifications for Horizontal End Suction Centrifugal Pumps for Chemical Process.
C. American National Standards Institute/Hydraulic Institute (ANSI/HI): 1. 1.1-1.5 - Centrifugal Pumps - Nomenclature, Definitions, Application and Operation. 2. 1.6 - Centrifugal Pump Tests. 3. 9.1-9.5 - Pumps - General Guidelines for Types, Definitions, Application and Sound Measurement.
D. American Society for Testing and Materials (ASTM): 1. A 108 - Standard Specification for Steel Bars, Carbon, Cold-Finished, Standard Quality. 2. A 276 - Standard Specification for Stainless and Heat Resisting Steel Bars and Shapes. 3. A 283 - Standard Specification for Low and Intermediate Tensile Strength Carbon Steel Plates. 4. A 395 - Ferritic Ductile Iron Pressure-Retaining Castings for Use at Elevated Temperatures. 5. A 494 - Specification for Castings, Nickel, and Nickel Alloy.
BC&A ANSI HORIZONTAL END SUCTION PUMPS JVWCD PAGE 11111-1 CENTRAL PIPELINE PROJECT 6. A 743 - Standard Specification for Casting, Iron-Chromium, Iron-Nickel, Corrosion Resistant, for General Application. 7. B 367 - Specification for Titanium and Titanium Alloy Castings. 8. E 10 - Test Method for Brinell Hardness of Metallic Materials.
1.3 DEFINITIONS
A. Pump Head (Total Dynamic Head), Flow Capacity, Pump Efficiency, Net Positive Suction Head Available, and Net Positive Suction Head Required: As defined in ANSI/HI 1.1-1.5 and 9.1-9.5 and as modified in this Section.
B. Suction Head: Gauge pressure available at pump intake flange or bell in feet of fluid above atmospheric; average when using multiple suction pressure taps, regardless of variation in individual taps.
C. Tolerances: In accordance with Hydraulic Institute 1.1-1.5, 1.6, and 9.1-9.5, unless specified more restrictively.
1.4 SYSTEM DESCRIPTION
A. Supply horizontal , centrifugal, ANSI/ASME B73.1 end suction, magnetic-drive pump. Non-metallic, lined magnetic drive pumps shall utilize ductile cast iron outer shell with injection molded liner and encapsulated inner rotating assembly, including a set of inner magnets within a containment shell or rear casing. Inner magnets are magnetically coupled or driven by outer magnet ring or drive magnet coupled to a conventional drive motor. Liquid end is hermetically sealed by static o-ring or gasket(s). Provide components as specified and other items as required for a complete and operational system. Pumps shall comply with the latest additions of the following codes and standards as specified herein: 1. ANSI B73.1 2. Hydraulic Institute Standards 3. National Electric Code (NEC) 4. OSHA Rules and Regulations
B. Design Requirements: 1. Pump Performance Characteristics: As specified in the Pump Schedule. 2. Motor Characteristics: As specified in the Pump Schedule.
1.5 SUBMITTALS
A. Submittals shall be provided in accordance with the requirements of Sections 01300 – Contractor Submittals and 11100 – Pumps, General.
1.6 QUALITY ASSURANCE
A. Testing shall be in accordance with the requirements of Section 11100 – Pumps, General.
B. Multiple pumps supplied under this Section shall be from the same manufacturer.
BC&A ANSI HORIZONTAL END SUCTION PUMPS JVWCD PAGE 11111-2 CENTRAL PIPELINE PROJECT C. Pump manufacturer shall furnish and coordinate pump, driver, and pump components as scheduled below and to provide written installation and check out requirements and procedures as part of submittal package.
1.7 WARRANTY
A. Pumps shall be provided with manufacturer standard warranty for minimum of one year from date of project substantial completion to cover parts, labor, shipping, and travel.
PART 2 PRODUCTS
2.1 MANUFACTURERS
A. Pump: One of the following or equal: 1. Goulds Pumps: Model 3298 S 2. Flowserve: Durco PolyChem, M-Series.
2.2 MATERIALS
A. General: Materials in the Pump Schedule shall be the type and grade as specified below.
B. Cast Iron: ASTM A 48, Class 30 minimum.
C. Ductile Iron: ASTM A 395.
D. Steel: ASTM A 108, Grade as scheduled.
E. Stainless Steel: ASTM A 276, type as scheduled.
F. Iron-Chromium Alloy: ASTM A 743, Grade CA40.
G. Structural Steel: ASTM A 283, Grade D.
H. Hastalloy C: ASTM A494, Grade CW-12M-2.
I. Titanium: ASTM B367, Grade C-3.
2.3 GENERAL PUMP CONSTRUCTION
A. Type: Horizontal centrifugal, seal less, end suction, magnetic-drive pumps manufactured in accordance with ANSI/ASME B73.1, except as modified in this Section.
B. Pumps shall be non-metallic, lined magnetic drive type, closed impeller design, 150# flanged suction and discharge connections, long-coupled design capable of back-pullout. All wetted parts shall be suitable for pumping and compatible with Hydofluosilicic Acid (up to 25% concentration).
C. Pumps shall comply with applicable sections of Hydraulic Institute Standards and ANSI B16.5 flange standards, unless otherwise noted.
BC&A ANSI HORIZONTAL END SUCTION PUMPS JVWCD PAGE 11111-3 CENTRAL PIPELINE PROJECT D. Pumps, drivers, and accessories shall be suitable for continuous operation at the specified operating conditions, and at flows ranging from the specified minimum flow to end-of-curve conditions.
E. Pump head-capacity curve characteristics shall rise continuously from rated capacity to specified minimum flow. Pump rated capacity shall not exceed capacity at the best efficiency point. Pump design and selection shall permit a 5% head increase at rated flow by installing a new impeller unless otherwise noted.
F. Required Net Positive Suction Head (NPSHr) shall be based on water. Available NPSHa shall exceed required NPSHr by a minimum of two feet
G. Any electrical drives or accessories shall be suitable for the specified electrical area classification.
H. Noise emission shall not exceed 85 dBA, 3 ft. from equipment surfaces.
2.4 PUMP CASINGS
A. Constructed of ductile iron (ASTM A395) and fully lined with a fluoropolymer PFA wet- end lining compatible with Hydrofluosilicic Acid (up to 25% concentration), minimum thickness of 1/8 inch.
B. Design Working Pressure: Minimum 1.10 times maximum shutoff total dynamic head with maximum installable impeller diameter at maximum operating speed plus maximum suction static head.
C. Hydrostatic Test: 10 minute hydrostatic test at minimum 1.5 times Design Working Pressure.
2.5 IMPELLERS
A. Impellers shall be closed, statically and dynamically balanced, completely coated with fluoropolymer PFA lining compatible with Hydrofluosilicic Acid (up to 25% concentration).
2.6 PUMP SHAFTS
A. The pump shaft shall be constructed of silicon carbide.
B. Strength: Able to withstand minimum 1.5 times maximum operating torque and other loads.
C. Solid shaft without sleeve.
2.7 BEARINGS AND BEARING FRAME
A. Bearing Type: The bearing shall be a one-piece design press fit into driven or inner magnet. Bearings shall be constructed of silicon carbide.
B. Bearing Life: In accordance with ANSI/ASME B73.1.
BC&A ANSI HORIZONTAL END SUCTION PUMPS JVWCD PAGE 11111-4 CENTRAL PIPELINE PROJECT 2.8 SUPPORTS, PEDESTALS, AND BASEPLATES
A. Type: Provide baseplate and supports in accordance with ANSI/ASME B73.1.
B. Materials: Corrosion resistant polymer concrete construction.
C. Pump and Driver Support Strength: Able to withstand imposed seismic loads, as specified in Contract Documents.
2.9 EQUIPMENT GUARDS
A. Provide equipment safety guards necessary to comply with OSHA Safety and Health Standards (29CFR1910). Where required for lubrication or maintenance access, guards shall have hinged and latched access doors.
2.10 DRIVERS
A. Horsepower: As scheduled. Listed driver horsepower is the minimum to be supplied. Increase driver horsepower if required to prevent driver overload while operating at any point of the supplied pump operating head-flow curve including runout. However, electrical equipment is sized for scheduled horsepower.
B. Motors: As scheduled and as specified in Section 16222 – Electric Motors.
2.11 DRIVEN MAGNET
A. The driven magnet shall be fully encapsulated with material compatible with Hydrofluosilicic Acid (up to 25% concentration). The bore of inner magnet shall have anti-rotation shape that mates to outside diameter of the press fit bearing.
2.12 DRIVE MAGNET
A. The drive or outer magnet shall be dynamically balanced and be capable of mounting directly to standard motors. Non-spark rubbing pads shall be provided.
2.13 FINISHES
A. Prepare surfaces and apply protective finishes as specified in Section 09900 – Coatings and Painting and 11100 – Pumps, General.
2.14 SPARE PARTS
A. Deliver spare parts in accordance with Section 11100 – Pumps, General and as follows for each pump: 1. One pump thrust bearing set. 2. One pump radial bearing set. 3. One motor bearing set of each type. 4. One set of all gaskets, seals, and o-rings.
BC&A ANSI HORIZONTAL END SUCTION PUMPS JVWCD PAGE 11111-5 CENTRAL PIPELINE PROJECT PART 3 EXECUTION
3.1 INSTALLATION
A. Install products in accordance with manufacturer's instructions and as specified in Section 11100 – Pumps, General.
B. CONTRACTOR shall furnish transition fittings to connect piping to pumps.
3.2 MANUFACTURER'S FIELD SERVICES
A. Manufacturer or certified manufacturer representative shall inspect system before initial start-up and certify that system has been correctly installed and prepared for start-up as specified in this section and Sections11100 – Pumps, General. Manufacturer shall provide training services to comply with the requirements specified in Section 11100 – Pumps, General.
3.3 PUMP SCHEDULE
Tag Numbers CPJN-P-03 General Characteristics: Service FA (25% conc.) Quantity 1 Maximum Noise, dBA at 3 feet 85 Minimum Pumped Fluid degrees Fahrenheit 50 Normal Pumped Fluid degrees Fahrenheit 70 Maximum Pumped Fluid degrees Fahrenheit 85 Pump Characteristics: Motor Horsepower (min hp) 0.5 Speed Control Constant Maximum Pump Revolutions per Minute 1750 Suction Flange Size, minimum (in.) 1.5 Discharge Flange Size, minimum (in.) 1.0 Rated Design Point (at maximum rpm): Flow, Gallons per Minute 15 Head, Feet 20 Minimum Efficiency, Percent 28
END OF SECTION
BC&A ANSI HORIZONTAL END SUCTION PUMPS JVWCD PAGE 11111-6 CENTRAL PIPELINE PROJECT SECTION 11258 CHEMICAL FEEDING EQUIPMENT, GENERAL
PART 1 – GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall provide chemical feeding equipment, including tote scales, calibration columns, sight glass, and other appurtenances, complete and operable, in accordance with the Contract Documents.
B. Equipment shall be from manufacturers with several years of experience in the manufacture and assembly of similar products, with a record of successful installations. Such manufacturers shall maintain a well-established, authorized, local service agency with sufficient spare parts and personnel to respond within 48 hours to any service calls.
C. The requirements of Section 11000 - Equipment General Provisions, apply to the Work of this Section.
D. Unless indicated otherwise, the requirements of this Section apply to all chemical feeding equipment in the Contract Documents.
1.2 CONTRACTOR SUBMITTALS
A. Furnish submittals in accordance with Section 01300 - Contractor Submittals and Section 11000 – Equipment General Provisions.
B. Shop Drawings: Complete fabrication, assembly, foundation, and installation drawings, together with detailed specifications and data covering materials used, power drive assemblies, parts, devices, pumps, tanks, mixers, supports, panels, and other accessories forming a part of the equipment, electrical schematics, diagrams, and panel layouts.
C. Certification: The Contractor shall obtain written certification from each manufacturer, addressed to the Owner, stating that the equipment will efficiently and thoroughly perform the required functions in accordance with these Specifications and the Drawings, and that the materials are best suited for the chemicals handled.
D. Technical Manuals: Furnish complete operations and maintenance manuals prior to equipment start-up.
E. Spare Parts List: The Contractor shall obtain from the manufacturer a list of suggested spare parts for each piece of equipment subject to wear, such as seals, packing, gaskets, nuts, bolts, washers, wear rings, etc.
F. Maintenance: Printed instructions relating to proper maintenance, including lubrication, and parts lists indicating the various parts by name, number, and diagram where necessary, shall be furnished in duplicate with each unit or set of identical units prior to equipment start-up.
BC&A CHEMICAL FEEDING EQUIPMENT, GENERAL JVWCD PAGE 11258-1 CENTRAL PIPELINE PROJECT G. Field Procedures: Instructions for field procedures for erection, adjustments, inspection, and testing shall be furnished prior to installation of the equipment.
H. Calibration Graphs: The manufacturer's representative shall prepare a calibration graph from field tests for each chemical feed unit which does not have a rate set device. Graphs shall read in pounds per hour for dry feeders or in gallons per hour for liquid feeders. The graph shall show the rate setter graduation conversion to pounds per hour or gallons per hour throughout the range of the feed unit. Each graph shall be furnished on hard paper and be sealed in clear plastic.
1.3 MANUFACTURER'S SERVICE REPRESENTATIVE
A. Installation and Startup Assistance: Service and instruction assistance by the manufacturer's engineering representative for each equipment unit shall be furnished by the CONTRACTOR during the following period:
1. One day during erection, unless indicated otherwise in the feed equipment section. 2. One day during startup, unless indicated otherwise in the feed equipment section.
B. Instruction of Owner's Personnel: The Contractor shall furnish the services of a factory service representative to instruct the Owner's personnel in the operation and maintenance of the equipment. This service shall consist of a minimum one day's visit to the plant for each type of similar equipment.
1.4 QUALITY ASSURANCE
A. Warranty: After acceptance of substantial completion, the Contractor shall furnish to the Owner the manufacturer's written guarantees that the equipment will operate with the published efficiencies, heads, criteria, and flow ranges and meet these specifications. The Contractor shall also furnish the manufacturer's warranties as published in its literature.
PART 2 – PRODUCTS
2.1 GENERAL
A. When required, a single manufacturer shall be responsible for the compatible and successful operation of the various components of any equipment unit, it shall be understood to mean that the Contractor shall provide only such equipment as the designated manufacturer will certify is suitable for use with its equipment and with the further understanding that this in no way constitutes a waiver of any indicated requirements.
B. Manufactured items provided under this Section shall be new, of current manufacture, and shall be the products of reputable manufacturers specializing in the manufacture of such products.
C. Where 2 or more units of the same type or size of equipment are required, such units shall be produced and supplied by the same manufacturer. BC&A CHEMICAL FEEDING EQUIPMENT, GENERAL JVWCD PAGE 11258-2 CENTRAL PIPELINE PROJECT
2.2 MATERIALS
A. Materials employed in the equipment shall be suitable for the intended application; materials not specifically called for shall be high-grade, standard commercial quality, free from defects and imperfections that might affect the serviceability of the product for the purpose for which it is intended.
B. The following table lists the most commonly used chemicals for water and wastewater treatment and some of the suitable materials for the construction of chemical feeding equipment. Unless the manufacturer proposes more suitable materials, the table shall be adhered to:
Chemical Suitable Handling Material
Polymers (Ionic) (Cationic ) (Nonionic ) Type 316 stainless steel PVC (100% solution) FRP (suitable grade, verify compatibility with manufacturer) Teflon Polypropylene
Citric Acid (50% Solution) Hastelloy C PVDF
FRP (suitable grade, verify compatibility with manufacturer) Viton Teflon Vinyl Saran Polypropylene
Sodium Hypochlorite (NaOCl) Hastelloy C Titanium (0.8 to 15 % solution) PVC FRP (suitable grade, verify compatibility with manufacturer) Viton Penton Hypalon Vinyl Saran Polyethylene Tyril Glass
BC&A CHEMICAL FEEDING EQUIPMENT, GENERAL JVWCD PAGE 11258-3 CENTRAL PIPELINE PROJECT 2.3 APPURTENANCES
A. Nameplate: Each piece of equipment shall be provided with a nameplate (of material compatible with chemical), indicating equipment characteristics, capacity, motor horsepower, speed, electrical characteristics, manufacturer, model number, serial number, etc.
B. Solenoid Valves: The equipment manufacturer shall provide solenoid valves, which are part of the chemical feeding unit. The solenoid valve electrical rating shall be compatible with the equipment voltage and valves shall be complete with the necessary conduit and wiring from the control panel to the solenoids. The valve material shall be suitable for the intended service in accordance with the Section 15230 -Miscellaneous Valves.
C. Pressure Gauges: Where indicated on Contract Drawings, chemical transfer and metering pumps and other equipment shall be equipped with pressure gauges with diaphragm seals in accordance with Section 17131 - Pressure Gauges, except that the size of gauges on small metering pumps may be smaller than indicated in that section.
D. Calibration Columns: Provide Calibration Columns as indicated on the Contract Drawings. Each Calibration Column shall be an acrylic tube with PVC heads. The columns shall be calibrated for 30 second sampling periods and shall have the capacity as indicated in the table below, and shall have a maximum height of 30 inches. Each column shall be securely supported at both top and bottom.
E. Sight Flow Sight Glass: Provide sight flow sight glass as indicated on the Contract Drawings. Each sight flow indicator shall be constructed of a PVC body with 150 # rated flanges. The indicator shall be a flutter type. The flow sight glass shall be manufactured by Jacoby Tarbox style 910-FA-FLTR or equal.
F. Tank Level Sight Gauge: Where indicated on Contract Drawings, chemical storage tanks shall be equipped with a tank level sight gauge. The sight level gauge shall be a flag type magnetic level gauge manufactured by John C Ernst Co. The wetted material shall be constructed of materials suitable for use with Fluorsilicic Acid (25% concentration).
G. Chemical Tank Discharge Connection Expansion Joints: Provide a custom flexible connection for each chemical tank discharge connection as shown on the contract drawings. The flexible connection shall be manufactured by Harrington Plastics or equal. The flexible connection shall consist of all nonmetallic materials: polypropylene braided overwrap, convoluted PTFE liner, and PVDF flanges. The flexible connection shall be a minimum length of 6-inches and shall allow for minimum horizontal and vertical deflection of 1-inch.
H. Equipment Supports: Chemical feeding equipment and piping shall be firmly supported on concrete equipment pads and anchored down. Supports shall be as shown on the Drawings and in accordance with Division 15 specifications.
I. Controls: Controls shall be housed in enclosures with NEMA ratings, which comply with the area designations of Section 16050 – Electrical General Provisions.
BC&A CHEMICAL FEEDING EQUIPMENT, GENERAL JVWCD PAGE 11258-4 CENTRAL PIPELINE PROJECT J. Safety Equipment: Where required by Code, chemical unloading, storage, and feeding equipment shall be provided with the necessary safety devices and warning signs, clearly visible. Signage shall be as specified in Section 10425 – Signs.
2.4 TOTE SCALES (CPJN-WE-01)
A. Provide and install a weigh scale, complete with one single channel indicator. The scale shall be of the single load cell design. Weight shall be transferred via a pivoted platform to a single load cell of the shear beam strain gauge type. Flexible cable shall be used to the connect load cell to indicator to allow easy remote installation of the readout. Supplied cable length shall be 48 inches.
B. The Contractor shall coordinate day tank anchoring and seismic control requirements with scale manufacturer to assure scale operation and accuracy is not jeopardized.
C. The tote scales shall meet the following minimum requirements:
Parameter Units Value
Maximum Weight Capacity lbs 2,000 Tote/Tank Size 34-inch dia Platform Size 40-inch x 40-inch Minimum Accuracy % 0.25 Platform Height inch 3
D. The tote scale shall have an electrical connection for 120 VAC power supply and shall capable of providing 4-20 mA output signal for monitoring.
E. The indicator shall be housed in a NEMA 4X, UL approved enclosure. The indicator shall display net remaining, daily usage, total amount used, rate of feed, days until empty, tare weight and gross weight. A data log function shall be included to store the daily usage for each of the previous 31 days. An operator shall be able to monitor chemical inventory by weight or in gallons by entering the specific gravity of the chemical. 1. Digital display shall have a 2 line, 16 characters per line, alpha-numeric LCD display with back lighting. Indicator shall be equipped with a 10 key numeric pad with tactile and audible feedback. All functions shall be menu prompted for ease of operation. 2. All zero and tare functions shall be set locally through the indicator.
F. Coatings: Chemical platform scales shall use a 2-component, 100% solids thermoplastic Polyurea hybrid coating system. Coating shall have a minimum dry thickness (DFT) of 80 mils. Coating shall have superior resistance to splash from acid and alkaline chemicals, resistance to chemical fumes and severe weathering or moisture. Coating shall exhibit maximum resistance to impact, abrasion and physical damage from loading chemical vessels. Material shall be a minimum density of 70 PCF as measured using ASTM test method D-1622, Taber abrasion resistance shall be a minimum of 0.10% per 1000 cycles per ASTM D-4060 and Shore hardness 45D per ASTM D-2240.
BC&A CHEMICAL FEEDING EQUIPMENT, GENERAL JVWCD PAGE 11258-5 CENTRAL PIPELINE PROJECT
G. The scale shall carry a Full Five (5) Year Factory Warranty. “Limited” warranties will be considered unacceptable.
H. Manufacturers: Force Flow, Model 40-DR20LP with Wizard 4000 electronic indicator.
2.5 TOOLS AND SPARE PARTS
A. Tools: Special tools necessary for maintenance and repair of the equipment and one pressure grease gun for each type of grease required for the equipment shall be furnished as a part of the WORK; such tools shall be suitably stored in metal tool boxes, and identified with the equipment number by means of stainless steel or solid plastic name tags attached to the box.
B. Spare Parts: Furnish spare seals, packing, gaskets, wear rings, and bearings as required by the feed equipment sections.
PART 3 – EXECUTION
3.1 INSTALLATION
A. General: Chemical feeding equipment shall be installed in accordance with governing safety standards, the Shop Drawings, and as indicated.
B. Alignment: Equipment shall be field tested to verify proper alignment, operation as indicated, and freedom from binding, scraping, vibration, shaft runout, leaks, or other defects. Drive shafts shall be measured just prior to assembly to ensure correct alignment without forcing. Equipment shall be secure in position and neat in appearance.
C. Lubricants: The Work shall include furnishing the necessary oil and grease for initial lubrication and testing of all equipment.
END OF SECTION
BC&A CHEMICAL FEEDING EQUIPMENT, GENERAL JVWCD PAGE 11258-6 CENTRAL PIPELINE PROJECT
DIVISION 13 SPECIAL CONSTRUCTION
SECTION 13115 IMPRESSED CURRENT CATHODIC PROTECTION
PART 1 GENERAL
1.01 WORK INCLUDED:
A. This section covers the work necessary to furnish and install an impressed current cathodic protection system and monitoring system, complete.
B. CONTRACTOR to furnish and install test stations, joint bonds, and electrical isolation as specified this section, concurrently with pipeline construction, complete.
1.02 STANDARDS
A. The following standards are included by reference: 1. NACE SP-0169 2. NACE SP-0177
1.03 QUALITY CONTROL
A. All CONTRACTOR specified testing shall be performed by a Corrosion Expert whom is NACE accredited as a Cathodic Protection Specialist (Level IV) or Cathodic Protection Technologist (Level III), or registered professional engineer with expertise in corrosion control and cathodic protection.
B. Contractor performed testing shall include the following tests, which shall be performed as defined this section.
1. Functional testing of cathodic protection stations 2. Joint Bond Resistance test 3. Casing Isolation testing (before and after casing fill) 4. Insulating Joint Testing 5. Concrete reinforcement isolation testing, if required.
C. Connection of galvanic anodes, energizing and testing of cathodic protection system, and other tests as defined under “System Tests and Inspections” shall be performed by the Engineer unless specifically stated otherwise this section.
1.04 DEFINITIONS
A. Active column: Active column of a Deep Well groundbed shall be that portion of the groundbed which discharges current, and consist of anodes and coke breeze.
B. Inactive column: Inactive column of a groundbed shall be that portion of the column that does not discharge current, and consist of the backfill, casing, and/or bentonite, grout, or concrete seal that is above the active column.
C. Foreign-Owned: Buried pipe or cable not specifically owned or operated by the OWNER.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-1 D. Electrically Continuous Pipeline: A pipeline which has a linear electrical resistance equal to or less than the sum of the resistance of the pipe plus the maximum allowable joint bond resistance for each bonded pipe joint as specified in this section.
E. Electrical Isolation: The condition of being electrically isolated from other metallic structures (including, but not limited to, piping, concrete reinforcement, and casings) and the environment as defined in NACE Recommended Practice SP0169.
1.05 SUBMITTALS:
A. Shop Drawings: Catalog cuts and other information for products proposed for use.
B. Quality Assurance Submittals: 1. Field Test Reports as specified for Contractor required testing. 2. Joint bond QC test reports 3. Qualifications of NACE Accredited Testing Personnel.
PART 2 MATERIALS
2.01 GENERAL:
A. Like items of materials provided hereunder shall be the end product of one manufacturer to achieve standardization for appearance, maintenance, and replacement.
B. Materials and workmanship as specified in this section shall be installed concurrently with pipe installation. Coordinate all work specified herein with related sections.
2.02 SUPPLIERS:
A. Alternate suppliers will be considered, subject to approval of the ENGINEER. Address given is that of the general office; contact these offices for information regarding the location of their representative nearest the project site. 1. Corrpro, Inc., Chicago, IL www.corrpro.com 2. Farwest Corrosion Control, Gardena, CA www.farwestcorrosion.com 3. Hoff Company, Inc. , Denver, CO www.pipelinesupplies.com 4. MESA Products, Tulsa, OK www.mesaproducts.com 5. Northtown Products, Huntington Beach, CA www.northtownproducts.com
2.03 JOINT BONDS
A. General: 1. All joint bonds provided either by pipe manufacturer or Contractor shall meet the following minimum requirements: a. All connections on a joint bond shall be welded or soldered. Mechanical or compression type connections shall not be permitted. b. Bonds and welds shall exhibit sufficient strength or flexibility to allow thermal movement of the pipe after pipe backfill without cracking or breakage. c. Bond connections to pipe shall be with an Engineer approved welding method. 2. All installed bonds shall be insulated or coated copper with all exposed copper field coated to prevent galvanic corrosion of the pipe.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-2 B. Ductile or Cast Iron Pipe: 1. Single-conductor, No. 2 AWG stranded copper wire with 600-volt HMWPE insulation, 18 inches long, with formed copper sleeve on each end of the wire. 2. Quantity of joint bonds per pipe joint shall be as defined below:
Bond Type Two Bonds Three Bonds Four Bonds #2 AWG Wire 16” or less 42” or less Over 42”
C. Coated Steel Pipe, External Bonds:
1. Rolled joint or Carnegie joint bonds shall be one of the following types at the CONTRACTOR’s option: a. Single-conductor, No. 2 AWG stranded copper wire with 600-volt HMWPE insulation, 18 inches long, with a formed copper sleeve on each end of the wire. Single conductor wire bonds are high profile bonds and will not be permitted under the heat shrink sleeve. b. Solid copper strap, 1-1/4-inch wide by 1/16-inch thick, equivalent to 1/0 AWG wire, with two punched holes for thermite welding to the pipe. Strap bond shall be 12-inches long. Strap holes shall be sized for the thermite weld mold and shall provide for physical centering of the mold over the hole. Copper strap bonds are low profile bonds and are suitable for installation under heat shrink sleeve with filler mastic or precoated bonds as specified below. 2. Quantity of joint bonds per pipe joint shall be as defined below:
Bond Type Two Bonds Three Bonds Four Bonds #2 AWG Wire NA 30” or less Under 60” Copper Strap 30” or less 60” or less Over 60”
3. Connection of joint bond to pipe shall be with the thermite weld method using the mold and cartridge and recommended by the bond manufacturer. 4. Bare copper strap bonds installed under heat shrink sleeves shall be provided with filler mastic between the bond and steel pipe to prevent dissimilar metal corrosion. Precoated copper strap bonds are available that will eliminate the need for filler mastic. 5. Bonds shall be as manufactured by Erico Products, Continental Industries, or approved equal. Third party manufactured bonds shall be approved by the Engineer for conformance with the requirements of this specification and proper thermite welding.
D. Flanged Joints: 1. Flange joint bonds shall be one of the following types at the CONTRACTOR’s option: a. Steel rod, 5/8-inch diameter, length as required, arc welded to edge of flange. b. Single-conductor, No. 2 AWG stranded copper wire with 600-volt HMWPE insulation, 18 inches long, with a formed copper sleeve on each end of the wire, thermite weld connections.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-3 2. Quantity of joint bonds per pipe joint shall be as defined below:
Bond Type Two Bonds Three Bonds Four Bonds Steel Rod 36” or less 72” or less Over 72” #2 AWG Wire NA 30” or less Under 60”
3. Coat steel rod bonds with fast curing epoxy after welding to joint as specified in this Section, except when pipe is specified to be coated in accordance with Section 09900, PAINTING.
E. Sleeve Coupling, Flanged Coupling Adapter, and Other Non-standard Joints: 1. Ductile Iron Pipe: a. No. 2 AWG wires, 24 inches long, HMWPE insulation, with two 12-inch long THHN insulated No. 10 AWG wire pigtails, as manufactured by Erico Products Inc. (Cadweld), Cleveland, OH. 2. Steel Pipe: a. Solid copper strap, 1-1/4-inch wide by 1/16-inch thick, equivalent to 1/0 AWG wire, with five punched holes for thermite welding to the coupling follower rings, middle, ring, and pipe. Strap bond shall be fabricated for the length of the coupling with sufficient additional length for 1 inch of joint movement. Strap holes shall be sized for the thermite weld mold and shall provide for physical centering of the mold over the hole. b. Connection of joint bond to pipe shall be with the thermite weld method using the mold and cartridge and recommended by the bond manufacturer. Strap bond shall be as manufactured by Erico Products, Continental Industries, or approved equal. Third party manufactured bonds shall be approved by the Engineer for conformance with the requirements of this specification and proper thermite welding. 3. Bond Quantity per Joint: Provide the quantity of bonds per pipe diameter as defined below:
Bond Type Two Bonds Three Bonds Four Bonds Copper Strap NA 60” or less Over 60” No. 2 Wire Bond NA 48” or less Over 48”
F. Insulated Flexible Coupling Joints: 1. Ductile Iron Pipe: No. 8 AWG wire, 18-inch long, with one 12-inch long THHN insulated No. 10 AWG wire pigtail. One bond per joint. 2. Steel Pipe: a. Solid copper strap, 1-1/4-inch wide by 1/16-inch thick, equivalent to 1/0 AWG wire, with four punched holes for thermite welding to the coupling and pipe. Strap bond shall be fabricated for the length of the coupling with sufficient additional length for 1 inch of joint movement. . Strap holes shall be sized for the thermite weld mold and shall provide for physical centering of the mold over the hole. b. Strap bond shall be as manufactured by Erico Products, Continental Industries, or approved equal. Third party manufactured bonds shall be
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-4 approved by the Engineer for conformance with the requirements of this specification and proper thermite welding. 3. Bond Quantity per Joint: Provide the quantity of bonds per pipe diameter as defined below:
Bond Type Two Bonds Three Bonds Four Bonds Copper Strap 30” or less 60” or less Over 60” No. 2 Wire Bond 30” or less 54” or less Over 54”
2.04 CATHODIC PROTECTION TEST STATIONS
A. Flush Style, Vehicular Traffic (Type 2): 1. Test Box: Concrete body cast with a cast iron ring, with a minimum weight of 55 pounds and minimum dimensions of 9-inch inside diameter and 12 inches long. 2. Furnish extensions as required to penetrate concrete surfaces by 4 inches minimum. 3. Furnish with a 14-pound cast iron lid with the words "CP Test" cast into the lid. 4. Manufacturer and Products: Brooks; Models 3RT or Christy Oldcastle Model G05, or equal.
B. Flush Style Terminal Boards: 1. Dimensions: 5-inch by 8-inch by 1/4 inch thick 2. Material: Phenolic, micarta, or fiberglass. 3. Terminals: Stainless steel bolts, double nuts, double flat washers, lock washer, and shunt. Quantity and placement as shown on the Drawings.. 4. Labels: Engrave terminal board with label of each terminal as shown on the Drawings and with the OWNER’s name and contact number.
C. Post Style, Steel Conduit: 1. Test Box: a. Cast aluminum with thread hub suitable for mounting to a 1-1/2-inch x 3-inch street reducer or directly to 3-inch rigid conduit. b. Manufacturer and Product: (1) Type T, C, and I Stations: Gerome Manufacturing, Testox 700 series (rectangle), except where Type TR stations required for remote monitoring capablity. (2) Type I-G, F, A, and TR Stations: Gerome Manufacturing, Testox 2000 series (rectangle) with 3” threaded hub. (3) Or equal. 2. Street Reducer: a. Hot dipped galvanized 1-1/2-inch x 3-inch street reducer. 3. Terminal Block: a. Plastic or glass-reinforced laminated, 1/4-inch thick with seven terminals. b. Terminal heads shall have special heads to keep them from turning or shall be easily accessible from both sides of the terminal block without requiring its removal. c. Terminal studs, washers, and nuts shall be stainless steel. 4. Mounting Structure: 3-inch rigid hot dipped galvanized steel conduit, 7 feet long, threaded one end (minimum).
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-5
D. Vault Mounted: 1. Test Box: a. Cast aluminum suitable for threaded mounting to a 1-inch or larger rigid galvanized steel conduit. b. Manufacturer and Product: (1) Gerome Manufacturing, Testox 700 series (rectangle) (2) or equal. 2. Terminal Block: a. Plastic or glass-reinforced laminate, 1/4-inch thick with five terminals. b. Terminal heads shall have special heads to keep them from turning or shall be easily accessible from both sides of the terminal block without requiring its removal. c. Terminal studs, washers, and nuts shall be stainless steel. 3. Hardware: a. Conduit - Hot dipped galvanized conduit and conduit bodies b. Mounts - Unistrut support or two piece, one hole, malleable iron strap and clamp back, O. Z. Gedney 14-100G and 143G or equal. Two hole straps will not be permitted.
2.05 REFERENCE ELECTRODES:
A. Prepackaged Copper-Copper Sulfate Reference Electrodes: 1. Material: Permanent type, copper-copper sulfate reference electrode suitable for direct burial with a minimum design life of 15 years. 2. Wire: No. 12 AWG stranded copper wire with yellow, 600-volt TW, THWN, or THHN insulation. The wire shall be attached to the electrode and insulated with the manufacturer's standard connection. Connection shall be stronger than the wire. 3. Backfill: Manufacturer's special low resistivity backfill in permeable cloth bag. 4. Packaging: Furnish electrode packaged in a plastic or heavy paper bag of sufficient thickness to protect the electrode, backfill, and cloth bag during normal shipping and handling.
2.06 CORROSION COUPON
A. Application: Provide at all remote monitoring capable test stations, Type F test stations, and where shown on the Drawings.
B. Coupon: 1. Steel corrosion coupon with IR drop free measurement capability. 2. Exposed steel area to be 0.01 square feet. 3. Provide with two #12 or #14 AWG stranded copper wires leads, green insulation.
C. Switch: 1. Magnetic reed switch, normally closed, with connecting leads and terminals. 2. EDI Model UI-MS, board or adjustable mount as required, with activating magnet.
D. Manufacturers: 1. Fink Probe as manufactured by Cott Manufacturing, 2. IR Free Coupon manufactured by M. C. Miller, 3. Or equal.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-6
2.07 WIRE:
A. Rectifier DC Wires: 1. No. 4 AWG wire shall be single-conductor, stranded copper wire with 600-volt, high molecular weight polyethylene (HMWPE) insulation, black.
B. Impressed Current Anode Wire: 1. Single-conductor, No. 8 AWG stranded copper. 2. Deep Well Anodes: 20-mil thick cross-linked Kynar or ECTFE floropolymer (Halar) primary insulation and high molecular weight polyethylene (HMWPE) outer insulation.
C. Pipe and Reference Electrode Wires: 1. No. 12 AWG wire, single-conductor, stranded copper with 600-volt XLPE, THWN, or HMWPE insulation. 2. Insulation Color: Color shall indicate the function of each test wire and shall be as follows: a. Pipe: White b. Reference electrodes: Yellow c. Casings: Orange d. Foreign Pipe: Blue (Water) or Red (Gas or oil) e. Insulating Joints: White and Green as shown on Drawings f. Corrosion Coupons: Green g. Anode Black
D. AC Power Service: 1. Disconnect to Rectifier: No. 8 AWG stranded copper wire, Type USE-2 or THWN cable with three conductors and ground wire. Colors in conformance with NEC requirements. 2. Underground Service: No. 8 AWG stranded copper wire, Type UF or USE-2 cable with three conductors and ground wire. 3. Overhead power service: No. 8 AWG stranded copper wire, UV resistant insulation, cable with three conductors and ground wire
E. Reference Electrode: No. 12 AWG wire single-conductor, stranded copper with 600- volt, XLPE, TW, THWN, or HMWPE insulation.
2.08 DEEP WELL GROUNDBED
A. Surface Casing 1. PVC well casing, conforming to ASTM F-480, Schedule 40.
B. Casing Sanitary Seal and Fill Material 1. General a. Sealing materials for wells shall conform to the State of Utah water well regulations or as specified herein, whichever is more stringent. 2. Sanitary Seal (annulus area between the surface casing and soil): a. Bentonite Grout: (1) Mixture of granular bentonite and water in a ratio of not less than 8 pounds of bentonite or expansive clay per gallon of water.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-7 (2) Slurry shall not be less than 50 percent expansive clay with the grain size of the remainder to be not greater than coarse sand. (3) Bentonite shall be commercially produced product specifically designed for well sealing. Acceptable products are Aquaguard, Quick-Grout, Plug-Gel, Shur-Gel, Enviro-Plug, or equivalent material. b. Unhydrated Bentonite Chips (1) Material: Unhydrated sodium bentonite, specifically designed for well sealing. (2) Gradation: Medium chips, 1/4 inch, minimum, to 3/8 inch, maximum, dust and fines not to exceed 2 percent by weight. (3) Application Restrictions: (a) Not allowed for sanitary sealing over 50 feet in depth, (b) Gravity feeding from the surface at depths greater than 30 feet will not be allowed without monitor probe to insure bentonite chips do not bridge and that hole fills from bottom to top. (c) Gravity feeding from the surface will not be allowed at any depth when static groundwater is present within annular space between casing and borehole. (4) Manufacturers: (a) Wyoming Ben, Enviroplug Medium (b) Baroid, Holeplug (c) Or Equal 3. Casing Fill (inactive column area): Unhydrated Bentonite chips.
C. Vent Pipe: 1. Active Column Vent a. Loresco “Allvent”, 1-inch diameter, solvent welded joints, slotted PVC vent pipe as manufactured by Cathodic Protection Equipment Company, Hattiesburg, MS. b. Slotted vent pipe shall be installed in the active anode column area and extend 15 feet into the inactive column. 2. Inactive Column Vent a. Inactive column vent pipe shall be 1-inch, schedule 40 PVC with solvent welded joints. 3. Surface Vent: a. ASTM A53-90b standard hot dipped galvanized steel pipe, 1-inch diameter with 180-degree gooseneck at the top. b. Coat threads and any damage to the galvanized coating with one coat of inorganic zinc rich primer.
D. Anode Centralizers 1. Metal assemblies that can be securely attached to the anodes to center them in the drilled well. 2. No sharp edges or bolts will be permitted on the centralizers. 3. Centralizers shall not block the well or impair installation of the anode, anode wires, or coke breeze.
E. Deep Well Seal: 1. Two-piece, cast iron seal with a rubber packer to form a watertight seal. 2. Seals shall permit conduit and vent pipe penetrations through the seal with the rubber packing sealing the annular space watertight. 3. Provide plugs for all unused holes.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-8 4. Seal installation shall be watertight. 5. Manufactured by Campbell Manufacturing, Inc., Bechtelsville, PA; Berkeley Pump Company; Jacuzzi Brothers Inc.; or equal.
2.09 IMPRESSED CURRENT ANODES
A. Cast Iron Anodes 1. Impressed current anodes for shall be Modified high silicon cast iron of the following alloy composition:
MODIFIED HIGH-SILICON CAST IRON
Silicon 14.20 to 14.75 percent Chromium 3.25 to 5.00 percent Manganese 1.50 percent, maximum Carbon 0.70 to 1.10 percent Copper 0.50 percent, maximum Molybdenum 0.20 percent, maximum Iron Remainder
2. Anodes shall be TA equivalent tubular anodes for center tapped anode wire connections as shown on the drawings. 3. Lead Wire: No. 8 AWG stranded copper with insulation as specified under WIRE, this section. Lead wire shall be of sufficient length to extend splice-free from anode connection to the anode junction box. Connection of lead wire to the anode shall be by the manufacturer's standard connection and shall be stronger than the wire. 4. Packaging: Lead wire shall be coiled and bound in such a manner as necessary to protect the insulation from damage during shipment. Anodes shall be protected from breakage. Damaged anodes or lead wire will be cause for replacement of the lead wire and anode. 5. Wire Labels: Label the end of each deep well anode wire with the anode number and lead wire length stamped onto brass tags. Number anodes sequentially from bottom to top.
2.10 COKE BREEZE:
A. Coke breeze shall be lubricated calcined petroleum of the following composition:
Volatile Matter 0.7 to 1.8 percent Ash 1.3 percent maximum Sulfur 1.9 percent maximum Fixed Carbon 95.0 percent minimum Particle Size 100 percent less than 16-mesh Density 68 pounds per cubic foot, minimum
B. Acceptable coke breeze shall be Loresco SC-3 as manufactured by Cathodic Protection Equipment Company, Hattiesburg, MS.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-9 2.11 ANODE JUNCTION BOX
A. Terminal Box: 1. NEMA 250-85, Type 4 or 4X, 14-gauge steel with minimum inside dimensions of 12 inches by 12 inches by 4 inches deep. 2. Hinged door with padlock hasp.
B. Hardware: Secure door with stainless steel quick release latches and hinges. Screw or bolt mounted or secured doors will not be acceptable.
C. Coating: Hot dipped galvanized in accordance with ASTM A153
D. Terminals and Connectors: Furnish a separate panel board, buss bar, and terminal strip or terminal block connectors, and nickel plated brass fasteners for connecting the anode lead terminals to the rectifier positive lead. Provide separate terminal and shunt for each anode lead. Quantity of terminals shall be as shown on the Drawings for quantity of anodes per groundbed.
E. Shunts: Holloway Type RS, 0.01 ohm.
F. Equipment Tags: Provide each junction box with original manufacturer’s equipment tag that identifies the original equipment manufacturer, model number, serial number, and any applicable electrical ratings. Equipment tags with vendor or distributor name will not be acceptable.
G. Manufacturer: Anode junction box shall be Universal Model ATB or ATB-S as manufactured by Universal Rectifiers Inc., Rosenberg, TX.
2.12 RECTIFIER:
A. Rectifiers shall be air cooled, manual controlled rectifier meeting NEMA MR-20-1958 standards.
B. Manual controlled output shall be controlled with a minimum of 24 evenly divided transformer tap settings.
C. The rectifiers shall be designed to operate continuously at full rated output at an ambient temperature of 45 degrees C with an AC input of 208 volts, single phase, 60- Hz. The rectifier shall be capable of operation at 110 percent of rated input without damage to the rectifier components.
D. Push button type circuit breakers for ac input or secondary ac breakers shall not be permitted.
E. The stack shall provide a continuous DC output of 40 volts, 12 amperes, minimum. The rectifying elements shall be a full wave bridge, silicon diode stack. The rectifier stack shall be protected from over voltage surge with metal oxide varisters and over current with current-limiting devices.
F. Lightning protection devices shall be provided on the ac input and dc output of rectifier.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-10 G. Supply the rectifier with separate DC voltage and current meter and external panel mounted shunt in series with the ammeter. The meters shall be accurate to within 2 percent of the actual voltage and current output and shall be d’varsonal-jeweled movement. Meters shall be tested and calibrated at the factory. Meters will be tested in the field for accuracy. The manufacturer shall replace inaccurate meters.
H. Transformer, ac circuit breaker, rectifier stacks, lightning arrestors, DC output meters, and all wiring connections shall be housed in an 11 -gauge steel, hot dipped galvanized cabinet suitable for pole mounting. The cabinet shall be provided with hinge doors on the front and one side with slide out rack assembly. Cabinet shall be provided with hasp for padlocking and shall be sealed to protect the interior components from weather, vandalism, and nest building insects.
I. Rectifiers shall be manufactured to include remote monitoring equipment connections and internal mercury relay switch for current interruption that are compatible with remote monitoring units specified, this section. Remote monitoring provisions supplied with rectifiers shall include:
1. Mercury relay switch with current capacity of 120 percent of the rated dc output, minimum, and compatible with remote monitoring equipment specified, this section. 2. Terminal strips with individual terminals for pipe test wire, reference electrodes, and power supply to remote monitoring equipment. 3. Power terminals shall be 115 volt ac power for remote monitoring unit, which is supplied from the primary side of rectifier breaker. Rectifier manufacturer to provide step down transformer for RMU power, when required. 4. AC power supply to remote monitoring unit shall be protected with an independent overload circuit breaker.
J. Remote monitoring connection terminals shall be provided by the rectifier manufacturer with double screw terminal strips mounted on the panel board for connection of remote monitoring equipment to be supplied by others. Terminal strip shall have all rectifier connections completed and terminated on the terminal strip with engraved identification or approved equivalent for the following connections:
1. Terminal Block No. 1 (Eight Terminals)
a. DC Volts, Positive b. DC Volts, Negative c. DC Shunt Millivolts, Positive d. DC Shunt Millivolts, Negative e. 115 volt ac Power Terminal #1 f. 115 volt ac Power Terminal #2 g. Relay Switch, Positive h. Relay Switch, Negative
2. Terminal Block No. 2 (Eight Terminals)
a. Reference #1 b. Pipe #1a c. Pipe #1b d. Reference #2
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-11 e. Pipe #2a f. Pipe #2b
K. Supply each rectifier with an operation and maintenance manual that includes an electrical schematic of the supplied rectifier, parts list with replacement part numbers, and troubleshooting procedures.
L. Provide each rectifier with original manufacturer’s equipment tag that identifies the original equipment manufacturer, rectifier model number, serial number, ac input, and dc output ratings. Equipment tags with vendor or distributor name will not be permitted and will be rejected and replaced by the CONTRACTOR.
M. Rectifier manufacturer shall be Universal Rectifiers Inc. Rosenberg, Texas.
2.13 AC POWER SERVICE:
A. Underground Power Service 1. Disconnect switch at rectifier shall be 120/240 volt, single phase, stainless steel safety disconnect with 20 ampere breaker. 2. Conduit: a. General: Must conform to electrical utility requirements b. Size: 2-inch diameter for secondary power or 3-inch diameter for primary power, 36-inch minimum long radius sweeps. c. Material: Rigid fiberglass or electrical grade Schedule 40 gray PVC.
B. Grounding 1. Ground Rod: Copper-clad steel, 5/8-inch diameter, 8-feet long. 2. Ground Wire and Clamp: No. 6 AWG solid copper wire with a high copper content alloy or bronze bolt-on ground rod clamp.
2.14 REMOTE MONITORING
A. CP Rectifier Remote Monitor 1. Provide Watchdog Model Scout remote monitoring unit (RMU) manufactured by Elecsys, Olathe, Kansas, with CDMA cellular telemetry and external antenna kit. 2. Supply one RMU per rectifier and provide all mounting hardware needed for external or internal mounting as required by the Owner or shown on the Drawings. 3. RMU shall have interruption capabilities compatible with the relay supplied with the rectifier. Contractor shall coordinate RMU supply power and relay electrical requirements with the rectifier manufacturer. 4. Contractor to connect RMU to rectifier and provide the following monitoring: a. Rectifier output voltage b. Rectifier output amperage c. Pipe to Soil Potential d. AC voltage detection e. Rectifier interruption relay
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-12 2.15 CONDUIT, LOCKNUTS, AND STRAPS:
A. Outdoors, Exposed Conduit 1. Rigid conduit shall be rigid galvanized steel. 2. Fittings, junction boxes, pull boxes, and outlet bodies shall be hot-dipped galvanized iron. 3. Locknuts, conduit clamps, and other miscellaneous hardware shall be hot dipped galvanized steel. Galvanized items shall be hot-dipped galvanized in accordance with ASTM A153. 4. Conduit clamps shall be two piece, malleable iron, one hole, strap and clamp back spacer, O. Z. Gedney 14-100G and 143G or similar, for mounting to surfaces with either lag bolts or concrete wedge anchors, as shown on the Drawings.
B. Buried Conduit: 1. Conduit shall be rigid electrical grade schedule 40 gray PVC. 2. Locknuts, two-hole straps, and other miscellaneous hardware shall be galvanized steel. Galvanized items shall be hot-dipped galvanized in accordance with ASTM A153.
C. Flexible conduit: 1. Flexible conduit for ac power from the entrance switch to the rectifier shall be PVC coated, waterproof flexible conduit. 2. Use of flexible conduit shall be minimized and shall be acceptable for use only where other fittings and elbows are not readily available.
2.16 PROTECTIVE BARRIERS
A. Bollards 1. Posts: Steel pipe, Schedule 40, 6-inch diameter, hot dipped galvanized in accordance with ASTM A153. 2. Reflective Tape: High intensity reflective tape, 5 mils minimum, yellow, 4-inch width. 3. Installation: As shown on Drawings.
2.17 THERMITE WELD MATERIALS:
A. General: 1. Thermite weld materials consist of wire sleeves, welders, and weld cartridges according to the weld manufacturer's recommendations for each wire size and pipe or fitting size and material. 2. Welding materials and equipment shall be the product of a single manufacturer. Interchanging materials of different manufacturers is not acceptable.
B. Molds: Graphite, as recommended by manufacture for pipe and wire size.
C. Adapter Sleeves: 1. For No. 12 AWG and No. 2 AWG wires. 2. Prefabricated factory sleeve joint bonds or bond wires with formed sleeves made in the field are acceptable. Attach field-formed joint bonds sleeves with the appropriate size and type of hammer die furnished by the thermite weld manufacturer. 3. Extend wire conductor 1/8 inch beyond the end of the adapter sleeve.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-13
D. Cartridges: 1. Steel: 32 grams, maximum. 2. Cast and Ductile Iron: 45 grams, maximum, XF-19 Alloy
E. Welders and Cartridges: For attaching copper wire to pipe material:
Cartridge Size, Pipe Material Weld Type Max. No. 6 AWG Wire & Smaller Steel HA, VS, HC 15 gm Ductile or Cast Iron HB, VH, HE 25 gm No. 4 AWG Wire & Smaller Steel HA, VS, HC 25 gm Ductile or Cast Iron HB, VH, HE 32 gm No. 2 Wire Joint Bonds Steel FS 32 gm Ductile or Cast Iron FC 45 gm Concrete Cylinder Pipe HA, GR 32 gm Copper Strap Joint Bonds Steel M-128 15 gm
F. Welding Materials Manufacturers: 1. Erico Products Inc. (Cadweld), Cleveland, OH. 2. Continental Industries, Inc. (Thermo-Weld), Tulsa, OK.
2.18 COATING REPAIR MATERIAL FOR PIPE AND FITTINGS
A. General: 1. Complete coating repairs in accordance with recommendations of the pipe or fitting manufacturer. 2. B. Coating Requirements: 1. Steel Pipe: a. Coal tar based coatings: Koppers Bitumastic 50 or Denso or Tapecoat wax tape coatings; or equal, 20 mils dry film thickness, minimum. b. Polyurethane or Epoxy Coatings: Fast cure epoxy, 20 mils dry film thickness, minimum c. Tape Wrap or Extruded Polyethylene Coating: Thermite Weld Cap, Canusa CRP Patch, or Raychem PERP patch, or equal d. Cement Mortar Coating: Same as required for Concrete Cylinder Pipe. 2. Ductile iron Pipe: a. Fast cure epoxy b. Thermite weld cap
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-14 3. Concrete Cylinder Pipe: a. Fast cure epoxy and 1-inch, minimum, cover of cement mortar.
C. Coating Materials: 1. Thermite Weld Caps: a. Royston Laboratories Handi-Cap IP, prefabricated primerless thermite weld cap and coating system. b. Provide primer unless specifically stated in product data sheet that no primer is required. 2. Fast Cure Epoxy Coating: a. 100 percent solids, fast curing epoxy suitable for submerged or buried conditions. b. Acceptable products or equal: (1) Denso Protal 7125 (low temperature) or Protal 7300 (2) Tapecoat TC 7010 (3) 3M ScotchKote 323
2.19 INSULATING JOINTS
A. General: Insulating joints shall be dielectric unions, flanges, or couplings. The complete assembly shall have an ANSI rating equal to or higher than that of the joint and pipeline. All materials shall be resistant for the intended exposure, operating temperatures, and products in the pipeline.
B. Insulating Flanges: 1. Gaskets: a. Full-face Type E, G-10 fiberglass with O-ring seal. b. Complete assembly shall have an ANSI rating of 150 pounds, minimum, or equal to or higher than that of the joint and pipeline. c. Gasket materials shall be resistant to intended chemical exposure, operating temperatures, and pressures in the pipeline. 2. Insulating Sleeves: Full-length Mylar or fiberglass reinforced epoxy (NEMA G-10 grade). 3. Insulating Washers: Fiberglass reinforced epoxy (NEMA G-10 grade). 4. Steel Washers: Plated, hot-rolled steel, 1/8-inch thick. Provide four steel washers per bolt for flanges 36-inch in diameter or greater. 5. Manufacturers: a. Pacific Seal, Inc., Burbank, CA. b. Central Plastics Co., Shawnee, OK.
C. Insulating Unions: O-ring sealed with molded and bonded insulating bushing to union body, as manufactured by Central Plastics Company, Shawnee, OK; or equal.
2.20 DC BLOCKING DEVICES
A. DC isolation devices shall be solid-state electronic devices capable of passing ac current while blocking dc current.
B. Device shall have electrical rating of 3KA fault current at 30 cycles and 40 amperes steady state ac current, minimum.
C. Device shall have symmetrical dc blocking capabilities of –2 volts to +2 volts.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-15
D. DC isolation devices shall be as manufactured by Dairyland Electrical Industries, Inc., Stoughton, Wisconsin.
2.21 CONCRETE
A. ASTM C94-90, Option A
B. Cement: ASTM C150-89, type II with minimum cement content of 564 pounds per cubic yard.
C. Coarse Aggregate Size: ¾ inches
D. Minimum Compressive Strength: 3,000 psi at 28 days with maximum water-cement ratio of 0.45.
E. Air Entrainment: 1. ASTM C260, nontoxic after 30 days and containing no chlorides. 2. Not less than 5 percent entrained air at the project site.
2.22 OTHER MISCELLANEOUS MATERIALS
A. Test Station Wire Terminations: One-piece, tin-plated crimp-on ring tongue connector as manufactured by Burndy Co. or Thomas and Betts.
B. Shunts: Shunts shall be 0.01-ohm Holloway Type RS.
PART 3 WORKMANSHIP
3.01 GENERAL:
A. The installation of the facilities herein specified and described shall conform to the latest applicable NEC rules.
B. The workmanship shall be of the highest grade and shall be in strict accordance with material manufacturer's instructions. Equipment or materials damaged in shipment or in the course of installation shall be replaced.
C. The CONTRACTOR shall examine all Drawings and coordinate his work so as to avoid conflicts, errors, delays, and unnecessary interference with the construction of the facilities and to avoid duplication of the work such as excavation, filling, etc. In the event of any conflicts in the Specifications, the ENGINEER shall be consulted.
3.02 STORAGE AND HANDLING:
A. Store all anodes off the ground and keep them dry at all times. Protect against weather, condensation, and mechanical damage.
B. Immediately remove from the project site all mechanically damaged anodes.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-16
3.03 PIPE JOINT BONDING
A. To form an electrically continuous pipeline and associated appurtenances, all steel and ductile iron pipe joints shall be electrically bonded; including buried, vault, and manhole pipe, fittings, and restrained joints; except threaded, welded, or insulated joints.
B. Install the quantity of joint bonds at each joint required to be bonded as specified this section or shown on the Drawings. Should the specifications and drawings conflict, the larger quantity will apply.
C. Multiple joint bonds shall be separate bonds. Attachment with common thermite welds will not be permitted.
D. Electrical connection of bonds to pipe and fittings shall be by thermite or arc welding process. Bolted, compression, or mechanical connections will not be permitted.
E. CONTRACTOR shall test each bonded joint for electrical resistance as specified under CONTRACTOR QUALITY CONTROL TESTING, this section.
3.04 TEST STATION INSTALLATION
A. General: 1. Test station location, type, and style shall be as shown on the Drawings. 2. CONTRACTOR may relocate test station up to ±25 feet for site conditions without ENGINEER approval. Relocation greater than ±25 feet must be approved by the ENGINEER. 3. CONTRACTOR to maintain records showing actual pipeline stationing of test station wire connections to the pipe. 4. Test stations shall be generally located as follows: a. Install Type T test stations or other type test stations as required or at 1/4 mile intervals, but not greater than 1,500 feet. b. Install a Type F test station where pipe crosses a foreign-owned metallic pipeline under cathodic protection. c. Install a Type C test station at both end of cased crossings. d. Install a Type I test station at all buried insulated joints. e. Install a Type A test station where galvanic anodes are required. 5. Locate post-mounted test stations directly over the pipe and, where possible, at protected locations such as fences, manholes, power poles, or edges of cultivated land. 6. Locate flush mounted test stations directly over the pipeline, except in areas of heavy traffic conditions or where indicated on the Drawings. Where heavy traffic conditions exist, offset the test stations to the side of the road or street.
B. Style: 1. Test station style shall be as shown on the Drawings and as follows: 2. Post mount style test stations shall be steel post style as shown on the Drawings. 3. Flush mount style test stations shall be used where indicated on the Drawings, or for test stations in roadways, landscaped areas, or where aesthetic requirements restricts the use of aboveground facilities.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-17 C. Installation: 1. Post mounted test station: a. Height shall be 42 inches above finish grade. b. In areas with livestock, test station height shall be between 48 to 60-inches. c. Post shall be concrete encased as shown on the Drawings. 2. Flush Mounted Test Stations a. Place in concrete pad or sidewalk with cast iron cover as shown on Drawings. b. Place concrete box on top of 3-inch base of compacted sand. c. In unimproved areas provide blue “Carsonite” utility marker with yellow reflector on each side 1 foot from test box or as directed by the ENGINEER.
D. Test Wires: 1. Wires shall be attached to the pipe as specified under WIRE CONNECTIONS, this section. 2. Test Wires to Foreign-Owned Pipelines: a. Wires to foreign pipe shall be connected by the CONTRACTOR unless the foreign pipeline owner requires installation by the foreign pipe operator. b. The CONTRACTOR shall coordinate test wire connections with the owner of the foreign pipeline. c. Where the foreign pipe operator refuses to install test wires, install a Type T test station and obtain a written release from the foreign pipe operator. 3. Wires shall be buried a minimum of 24 inches below finished grade, except in undeveloped or cultivated areas where the wires shall be a minimum of 30-inches below finish grade. 4. Wires shall be direct buried except when station is offset to the side of a road or trail. Offset wires shall be installed in PVC coated rigid steel conduit from the centerline of the pipeline to the back of curb or test station, whichever is least. 5. Provide 12-inch diameter loop in wires at the pipeline connection, at each end of rigid conduit when required, and below post mounted test stations to prevent wires from being stressed or broken. 6. Maintain sufficient slack in flush mount test wires to permit extension of terminal block 18-inches from station. 7. Make wire connections to test station terminals with crimp-on ring tongue terminals, except where solid wire is specified.
3.05 REFERENCE ELECTRODE INSTALLATION
A. Remove plastic or paper wrapper and place reference electrode within the pipeline trench excavation 6 inches below the centerline of the pipe in a vertical position.
B. Install reference electrode centered between foreign pipelines and OWNER’s pipeline at pipe crossing location.
C. Install packaged reference cell dry and lower into hole by rope sling or by grasping cloth gather. Do not use reference cell lead wire in lowering anodes.
D. Backfill hole with select native material in 6-inch layers and hand tamp each layer around anode. Use only native soil for backfill; do not use sand. Exercise care not to strike reference cell or lead wire with tamper.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-18 E. Add water only after backfilling and tamping has been completed to a point six inches above reference cell. Pour approximately five gallons of water into hole. After water has been absorbed by soil, complete backfilling and tamping to top of hole.
F. Terminate reference electrode wire in test station.
3.06 CORROSION COUPON INSTALLATION
A. Place corrosion coupons within 6-inches of pipe and reference electrode.
B. Install reference electrode centered between foreign pipelines and OWNER’s pipeline at pipe crossing locations.
C. Terminate corrosion coupon lead wires in test station on separate terminals.
D. Connect coupon to pipeline with magnetic switch as specified and shown on drawings.
3.07 RECTIFIER INSTALLATION:
A. The CONTRACTOR shall provide the rectifier mounting pole, ac power service to the rectifier, and all ac and dc electrical hardware necessary for the rectifier installation.
B. The rectifier installation and location shall be as shown on the Drawings, except when the Drawings and local or State electrical codes are contradictory. In such cases, local or State electrical codes shall prevail. The CONTRACTOR shall coordinate, install, and connect an ac power service to each rectifier location.
C. Dc leads to the rectifier shall be as specified this section and shown on the Drawings. Wires shall be buried a minimum of 30 inches below finished grade. All rectifier leads shall be free of splices. Insulation on rectifier leads shall be free of cuts or abraded areas.
D. Provide two pipe test lead wires and one reference electrode to the rectifier and terminate on the rectifier panel board.
E. Provide the ENGINEER with 10 working days prior notice of the completion of the rectifier and groundbed installation for observation of CONTRACTOR performed functional test of the completed system.
3.08 AC SERVICE:
A. General 1. Electrical power service shall be installed by the CONTRACTOR in accordance with local electrical utility requirements and shall meet or exceed local or NEC codes. 2. Electrical service shall be underground unless shown otherwise on the Drawings. 3. Electrical service shall be installed by a licensed electrician. 4. CONTRACTOR shall obtain a local building permit and coordinate inspection of the completed electrical service.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-19 B. Underground Service 1. CONTRACTOR shall provide all materials, trenching, backfill, compaction, conduit, and equipment bases necessary for installation of a conduit from the originating power pole or source to the meter pedestal or self supporting electrical service panel. 2. Underground service shall be installed in conduit, buried 24 inches, minimum, below finish grade in sand backfill as shown on Drawings. 3. Underground conduit shall not be greater than 250 feet long and contain more then 270 degrees of combined bends between pull boxes without written approval of the Engineer. 4. Conduit shall be free of dirt and debris, sealed to prevent infiltration of water, and ends capped.
3.09 DEEP WELL GROUNDBED INSTALLATION:
A. General: 1. Drilling, electrical logging of well, lowering of anodes, coke breeze placement, and backfilling shall be done in a continuous operation and shall be observed by the ENGINEER. 2. CONTRACTOR shall be a certified water well driller in current standing in the state of Utah and shall obtain all drilling permits, submit notification of work, and submit drilling logs in accordance with state regulations. 3. Driller will be solely responsible for all aspects of the drilling and well construction until the well completion. 4. Drilling of the groundbed shall be in accordance with the methods and procedures of the best recognized drilling practices and shall comply with the rules and regulations of the State, County, City, or other governing bodies having jurisdiction. 5. Deep Well groundbeds shall be sealed as specified herein or as required by well drilling regulations. The most stringent requirements shall apply. 6. Take necessary precautions to avoid entrance of foreign matter, movement of soil strata, or collapsing of the well during the progress of the work. Should movement of soil strata or collapse of the drilled well interfere with proper completion of the ground bed, recover the wires and anode strings if necessary and ream or redrill the well. 7. The driller shall maintain a log describing the depth and type of formations encountered during drilling. Copies of the log shall be submitted to the ENGINEER and appropriate authorities. 8. Wells not completed in accordance with the State of Utah well regulations and these specifications will be subject to rejection and replacement at the CONTRACTOR’s sole expense.
B. Drilling: 1. Coordinate the actual location of the ground bed in the field with the ENGINEER before drilling begins. Verify and locate all buried utilities prior to beginning drilling operations. 2. CONTRACTOR shall provide a holding sump to contain and store drilling fluids and cuttings. Excavation of a temporary mud pit on the project site will not be permitted. CONTRACTOR shall transport and dispose of all drilling fluids and cuttings to an approved disposal location.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-20 3. CONTRACTOR shall provide drilling mud containment and disposal system to prevent mud from entering drainages, storm drains, gutters, streams, or leaving the project site. 4. CONTRACTOR shall size the holding sump for the project and take all precautions necessary to prevent spillage or overflow of drilling fluids. All overflow or spillage shall be contained. CONTRACTOR shall be responsible for cleaning up all spills and overflows and, if necessary, will clean drainages, storm drains, and manholes impacted by uncontained drilling fluids. 5. Spillage or leakage of oil or hydraulic fluids shall be contained and controlled by the Driller. All oil contamination on the drilling site resulting from drilling equipment shall be contained, cleaned up, and properly disposed off the project site. 6. Construct the well and set casing straight and plumb. 7. Set surface casing shall be prior to completion of the first 100 feet of the well. Casing, other than surface casing, shall not be installed or left in the well unless in the driller’s estimation it is necessary for successful completion of the well. Plastic casing may be installed in the inactive column, at the CONTRACTOR’s option, but shall not extend into the active column. 8. If steel casing is installed into the active column, it shall be cut 100 feet below the surface and the top portion jacked up to provide a 25 foot, minimum, separation between the upper casing and the top of the active column. Complete cutting of the steel casing before anodes are installed. Jacking operations may be completed before or after installation of anodes at the CONTRACTOR's option. 9. Over drill the well to compensate for sloughing or heaving during anode installation.
C. Electrical Logging: 1. Flush the well and electrically log the well in the presence of the ENGINEER to determine the soil characteristic along the length of the well. 2. Electrical Logging Method: Measure current output of first anode as it is lowered into the well. Test using suitable meters, connections to a low resistance ground, and a method to measure the down hole wire length or provide footage identification markings on the wire. 3. Record current output readings and depth from the surface continuously or at 5- foot increments for the entire well depth. Note depth of groundwater at time of electrical logging.
D. Lowering of Anodes: 1. Anode installation to be observed by the ENGINEER 2. Install anodes and coke breeze the same day as the completion of the drilling and electrical logging. If loading is delayed more than 8 hours after drilling is completed or if loading cannot be completed before sunset or end of working hours, whichever comes first, the drill stem and bit should be reinserted and run back to the bottom of the well with sufficient rotation and circulation to ensure that the drilled well is prepared for anode installation. 3. If the well is drilled with mud, the well shall be flushed out with clean water in a continuous process before or after the anodes are lowered, at the CONTRACTOR’s option, until the return fluid is sufficiently clear and has a weight per gallon not greater than 9.2 pounds for proper settlement of the coke. The ENGINEER shall inspect the return fluid before coke breeze pumping will be permitted to begin.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-21 4. Attach anode centralizers to each of the anodes prior to lowering. Attach deepest anode to the vent pipe. Lower anode and vent pipe to the bottom of the well. Lower the remaining anodes individually until all anodes are suspended in the well. 5. The bottom of the vent pipe shall be capped and each joint of pipe solvent welded in accordance with the manufacturer’s recommendations. Drilling of the vent pipe to prevent floating is prohibited and will result in rejection of the vent pipe. 6. CONTRACTOR shall prevent foreign matter from entering the vent pipe during anode installation and grout sealing placement. The CONTRACTOR shall clear any blockage of the vent pipe. Failure to clear the vent pipe will result in rejection of the ground bed. Vent pipe shall be permitted to flow water during coke breeze pumping to flush any mud and cuttings from the vent. 7. Any damage to anodes or cut, gouged, or scraped wire insulation will result in rejection of the anode and lead wire. CONTRACTOR shall implement means to protect the anode lead wires during and following anode installation.
E. Backfilling of Anode Well: 1. Keep well full of water during installation of the coke breeze. 2. Prepare coke breeze slurry with potable water in accordance with the manufacturer’s written recommendations. Pump the slurry into the well through a steel or plastic tremie pipe. Pump coke breeze in an even and continuous manner from the bottom of the well to the top as the tremie pipe is slowly withdrawn. Top- loading the coke breeze, by pouring coke breeze into the well will not be permitted. 3. Throughout coke breeze pumping, displaced water and mud shall be collected and stored for disposal. Discharge of mud and water into the storm drains or public right-of-ways, or roadways will not be allowed. CONTRACTOR will be responsible to determine and provide the storage capacity required. Should the water and mud storage capacity be inadequate for the project, work will be terminated until adequate capacity is provided. Loss of materials or collapse of the well due to termination of the loading operation will be at the CONTRACTOR’s sole expense. 4. Care shall be taken during pumping of the coke breeze to avoid coke breeze bridging or collapse of the well. If the well collapses or coke breeze bridges, the CONTRACTOR shall take necessary steps to resolve the problem at his sole expense. 5. Restrain anodes from settling during and following coke breeze installation for 24 hours, minimum, for coke breeze settlement and compaction. Maintain anode restraint until all anode settlement stops. 6. After the coke breeze is installed and has settled for 24 hours the ENGINEER shall measure the depth to the top of the coke breeze column. If required, additional coke breeze shall be added by pumping or top loading to the specified elevation. Coke breeze shall not be less than 100 feet below finished grade elevation. CONTRACTOR shall remove any excess coke breeze at his sole expense. 7. When the coke breeze has properly settled and has been placed to the proper depth, fill the inactive column with the specified sealing material to within 4 feet of ground surface.
F. Placement of Casing Seals: 1. Sanitary Casing Seal a. Install sanitary seal in annular space between casing and soil. b. Place casing sanitary seal by tremie pipe and pumping if well is greater than 25 feet or groundwater is present within the well. c. The seal placement shall be done continuously and in a manner that will ensure the entire filling of the annular space in one operation.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-22 d. No drilling operations will be permitted until the neat cement or grout has cured. Curing time for portland cement, Type I or II, is a minimum of 72 hours and for type III a minimum of 36 hours. Addition of an accelerator will be permitted subject to written approval from the State Water Engineer. 2. Casing Seal a. After the coke breeze settlement is completed and anode settlement is stopped, the casing shall be filled with the specified sealing material. b. Placement of the sealing material will be with plastic tremie pipe only for slurry type seals. Inserting of the tremie pipe shall be performed in a manner that will not damage the wire insulation. c. Granular sealing materials may be top loaded, but shall be performed at a rate that will not result in bridging of the seal material.
G. Anode Wire Terminations: 1. The CONTRACTOR shall cut a smooth hole in the side of the casing for routing wires to the anode junction box. All below grade penetrations of the surface casing shall be watertight. 2. Anode wires shall be installed in conduit from the ground bed to the anode junction box. The completed electrical conduit shall be watertight. 3. Seal both ends of all conduits from the ground bed with urethane foam to prevent ground bed gases from entering the conduit, anode junction box, or rectifier. 4. Anode lead shall be terminated in numerical order in correspondence to anode depth.
H. Groundbed and Vent Pipe Termination: 1. Connect the surface pipe directly to the plastic vent pipe with a solvent welded by threaded connection adapter. 2. Terminated vent pipe as shown on the Drawings. 3. After all wire terminations and vent pipe connections are completed, complete filling of the inactive column with the specified sealing material. 4. Plumb and support vent pipe during seal placement and while the seal sets or compacts.
I. Cleanup: 1. The drilling site shall be kept neat and orderly under all circumstances. 2. All excess equipment and cuttings shall be removed daily when required by the prevailing conditions at the drilling site. The CONTRACTOR shall remove all mud, waste products, and tailings from the project site and dispose of at an approved disposal site. 3. The project sites shall be restored to a condition equivalent to their original condition before construction started and to the satisfaction of the ENGINEER. Damage to sidewalks, curbs, roads, and driveways shall be restored to original condition or better.
3.10 ANODE TERMINAL BOX INSTALLATION
A. Connect the rectifier positive wire and anode wires to the anode junction box terminals.
B. Label wires in the terminal box with permanent brass tags identifying the anode number and rectifier lead. Connect numbered anodes in consecutive order from top to bottom with anode terminals starting at number 1 on the top left-hand side.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-23 C. Maintain sufficient slack to keep the wire from being unduly stressed, damaged, or broken during backfill.
D. All conduits entering the anode junction box shall be sealed with urethane foam to prevent groundbed gases from entering the junction box.
3.11 THERMITE WELD WIRE CONNECTIONS:
A. Use thermite weld method for electrical connection of copper wire to steel, ductile iron, and cast iron surfaces. Observe proper safety precautions, welding procedures, thermite weld material selection, and surface preparation as recommended by the material manufacturer. Assure that pipe or fitting wall thickness is of sufficient thickness that the thermite weld process will not damage the pipe or fitting wall's integrity or damage the lining in any way.
B. Before the connection is made, the surface shall be cleaned to bare metal by making a 2-inch by 2-inch window in the coating, and then filing or grinding the surface with a vitrified wheel to produce a bright metal finish. Wire sleeves shall be installed on the ends of the wire before welding to the metal surface.
C. After the weld connection is cooled, remove slag, visually inspect, and physically test wire connection by tapping with a hammer. Remove and replace any defective connections.
D. Make wire connections to concrete cylinder pipe by thermite welding to the shop welded steel plates provided on the pipe for this purpose.
E. Coat each completed wire connection as specified, this section. If lining is damaged by welding, repaired in accordance with the lining applicator's recommendations.
3.12 TRENCHING AND BACKFILL
A. Complete excavations and trenching regardless of the type, nature, or condition of materials encountered, and as required to accomplish specified construction to lines and grades shown.
B. Take care to avoid damage to existing structures and utilities during excavating and trenching process. CONTRACTOR may modify location, where approved by the ENGINEER, to minimize possible damage to existing structures. Trench shall be of uniform depth and width, level, smooth, and free of sharp objects.
C. Slope, shore, or brace excavations and trenches in accordance with OSHA regulations as necessary to prevent caving during excavation in unstable material, or to protect adjacent structures, property, workers, and the public.
D. Backfill trench with excavated backfill materials, unless otherwise specified. Compaction requirements shall be as specified for the pipeline or to 90 percent of modified proctor, whichever is more stringent. Backfill within 5 feet of roadways, paved areas, or other traffic areas shall be compacted to 95 percent of modified proctor.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-24 E. Do not use backfill material of frozen or consolidated debris. Leave the trench with the excess backfill material neatly mounded not more than 4 inches above the existing ground level for the entire width of the trench.
3.13 CONDUITS
A. Secure conduits entering cabinets, junction boxes, or terminal boxes with double locknuts, one on the outside and one on the inside.
B. Install conduit parallel to walls, floors, or posts, and either plumb or horizontal. All changes in direction shall be at 90 degrees using either radius bends or outlet boxes. Conduit crossings shall be perpendicular to the other conduit or pipe.
C. Install insulated bushings and insulated throat connectors on the ends of rigid metallic conduit.
D. Use watertight couplings and connections. Install and equip boxes and fittings to prevent water from entering the conduit or box. Seal unused openings.
3.14 CONCRETE:
A. Concrete used for slabs shall conform to the requirements for concrete in Section CONCRETE.
B. CONTRACTOR shall finish all concrete work to a smooth trowelled finish with radius edges.
C. All forms shall be removed from concrete work prior to final acceptance and removed from the project site.
3.15 SURFACE RESTORATION:
A. Surface restoration shall be in accordance with Section SURFACE RESTORATION and as shown on the Drawings.
3.16 WIRE INSULATION REPAIR
A. Underground splicing of wire will not be permitted, except where specifically shown on the drawings and approved by the ENGINEER.
B. Where splicing is approved by the ENGINEER, splices shall mechanically secure and soldered with rosin cored 50/50 solder. Compression connectors will not be permitted.
C. Splices or insulation damage to test station wires shall be spirally wrapped with two coats of high-voltage self-vulcanizing rubber splice tape and two layers of vinyl electrical tape.
3.17 INSULATED JOINTS
A. Install insulated joints to electrically isolate the pipeline from other pipes or structures where shown on the Drawings.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-25 B. Install insulated joints as shown on the Drawings.
C. Align and install insulating joints according to the manufacturer's recommendations to avoid damaging insulating materials.
D. Install a Type I test station at each buried insulated joint.
E. Provide a DC blocking device on all insulating joints, except buried joints, as specified herein and shown on the Drawings.
F. The CONTRACTOR shall test each insulated joint for electrical insulation as specified this section. Defective insulating joints shall be repaired by the CONTRACTOR at his sole expense. All damaged or defective insulation parts shall be replaced.
3.18 DC BLOCKING DEVICES
A. Install dc blocking devices in ground wire at all motor operated valves and where indicated on the Drawings.
B. DC blocking devices be installed at each electrical power connection to the pipeline and shall be placed as close to the pipe as reasonable possible and shall have no conduit supports between the pipe and the dc blocking device as shown on the Drawings.
C. Wires between the pipe and dc blocking device shall be maintained at the shortest length reasonably possible for lightning protection requirements.
D. Support of dc blocking device shall be on either a 2-inch diameter hot-dipped galvanized steel pipe support, 4-inch hot dipped galvanized channel support, or shall be mounted to a concrete wall at the CONTRACTOR’s option. ENGINEER shall review and approve the applicable equipment support based on the conditions present.
E. All electrical conduits connecting or attaching to the pipeline shall be electrically isolated from pipeline. Conduit connections to the pipe or equipment mounted on the pipe or associated appurtenances shall be electrically isolated with an insulating union located within 6-inches of the connection and shall have no conduit supports between the insulating union and the pipeline.
F. CONTRACTOR is responsible for proper installation of dc blocking devices and electrical conduit isolation where necessary to achieve complete electrical isolation of all electrical grounding from the pipeline.
G. The CONTRACTOR shall be responsible for requesting installation guidance from the ENGINEER under complex field conditions, where grounding isolation cannot be achieved, or clarification of the electrical isolation requirements are needed.
H. Upon completion of electrical system ground isolation from the pipeline, the ENGINEER shall review the completed installation for proper installation. Improperly installed conduit isolation or dc blocking devices shall be corrected at the CONTRACTOR’s sole expense.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-26
3.19 QUALITY CONTROL TESTING
A. General:
1. Contractor shall correct all construction defects identified during testing. 2. Provide engineer with 7 days advance notice of completion for Engineer acceptance testing. 3. Contractor required testing as defined herein shall be performed by a Corrosion Expert, with qualifications as specified this section, whom is an employee or subcontractor to the Contractor.
B. Joint Bond Resistance Test:
1. General a. The CONTRACTOR shall test completed joint bonds for electrical continuity using a digital low resistance ohmmeter. b. Joint bond quality control test shall be performed on all bonded joints after the bonds are installed but before backfilling of the pipe. c. Furnish all equipment and materials as required for test. d. Corrosion Expert shall provide field training on proper instrument use and joint bond resistance measurements to CONTRACTOR personnel whom will be performing joint bond installation.
2. Digital Low Resistance Ohmmeter Test Method: a. Required Equipment And Materials: (1) One Biddle Model 247002 digital low resistance ohmmeter. (2) One set of duplex helical current and potential handspikes, Biddle Model No. 242011-7, with seven foot cable length or as required. b. Test Procedure: (1) Measure the resistance of joint bonds with the low resistance ohmmeter in accordance with the manufacturer's written instructions. (2) Use the helical handspikes to contact the pipe on each side of the joint, without touching the thermite weld or the bond. The contact area shall be cleaned to bright metal by filing or grinding and without any surface rusting or oxidation. (3) Record the measured joint bond resistance on the test form described herein. (4) Repair any damaged pipe coating in accordance with WIRE CONNECTIONS, this section.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-27
3. Joint Bond Acceptance: a. Joint bond resistance shall be less than or equal to the maximum allowable bond resistance values shown below.
Max. Allowable Resistance (micro-ohms) Two Three Four Joint Type Bonds/Joint Bonds/Joint Bonds/Joint No. 2 AWG wire Bonds 162 108 81 Copper Strap (12-inch) 165 83 55 Copper Strap (6-inch) 83 55 41 Flexible Coupling 212 142 106 MLC Steel Pipe Clips 110 55 42 Z-bars 142 95 71 Flange Steel Rods NA NA NA
b. For bond quantities greater than shown above obtain maximum allowable bond resistance from the Engineer. c. The CONTRACTOR shall remove and replace all joint bonds on a joint that exceeds the maximum allowable resistance. Replacement joint bonds shall be retested for compliance with the specified bond resistance. d. Any defective joint bond discovered during SYSTEM TESTS AND INSPECTION shall be located, excavated, repaired, and backfilled by the CONTRACTOR.
4. Test Records: Records shall be made of each bonded pipeline during the test and submitted to the ENGINEER. These records shall include: a. Description and location of the pipeline tested. b. Starting location and direction of test. c. Date of test. d. Joint type. e. Measured joint bond resistance
5. Report: CONTRACTOR shall submit a QC report upon completion of joint bond resistance testing which includes the information listed above.
C. Insulated Joint Isolation Test:
1. CONTRACTOR shall provide a Corrosion Expert to test each insulating joint after assembly with a GAS Electronics Model 601 insulator tester or equivalent instrument in accordance with the manufacturer's written instructions. 2. The Corrosion Expert shall conduct additional insulating joint testing as required to insure that insulating flanges are not electrically shorted by other equipment or incidental contact with concrete reinforcement. 3. Conduct test before burial and coating of buried insulating flanges.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-28 4. CONTRACTOR to replace damaged or defective insulation parts identified during testing. 5. Electrical Isolation is defined as a condition of being electrically isolated from other metallic structures (including, but not limited to, other piping, concrete reinforcement, casings, and other structures not intended to be cathodically protected) and the environment as defined in NACE Recommended Practice RP0169-83. 6. CONTRACTOR shall submit a report prepared by the Corrosion Expert certifying insulating joint testing isolation, test method(s), test data, and any corrective action required.
D. Casing Isolation Testing:
1. CONTRACTOR to test each casing and carrier pipe after assembly for electrical isolation before and after filling of casing with the specified fill material. 2. An electrical isolation test method and evaluation criterion to be utilized by Corrosion Expert is to be submitted in writing for approval by ENGINEER prior to beginning field testing. 3. Electrical Isolation is defined as a condition of being electrically isolated from other metallic structures (including, but not limited to, other piping, concrete reinforcement, casings, and other structures not intended to be cathodically protected) and the environment as defined in NACE Recommended Practice RP0169-83. 4. CONTRACTOR to conduct any and all remedial actions necessary to clear all electrical contacts between the carrier pipe and casing before filling of the casing shall be permitted. 5. CONTRACTOR shall submit a written report prepared by the Corrosion Expert certifying casing isolation, testing method(s), test data, and any corrective action required.
E. Concrete Reinforcement Isolation Test:
1. Pipe penetrations as listed below shall be tested for electrical isolation from electrical grounding and concrete reinforcement by a Corrosion Expert.
2. Contractor to perform concrete reinforcement isolation tests where concrete reinforcement isolation is required on the Drawings.
3. Electrical isolation test method and evaluation criterion to be utilized by Corrosion Expert is to be submitted in writing for approval by ENGINEER prior to beginning field testing.
4. Testing shall be conducted prior to concrete placement and shall be monitored during concrete placement to ensure no electrical shorts between the pipe and tank occur.
5. Corrosion Expert shall prepare a report certifying the concrete reinforcement is properly isolated and describe test method used to verify electrical isolation upon completion of the isolation test.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-29 6. Electrical shorted detected and identified during Engineer performed SYSTEM TESTS AND INSPECTIONS, shall be located and repaired by the Contractor at Contractor’s sole expense. 7. CONTRACTOR shall submit a written report prepared by the Corrosion Expert certifying concrete reinforcement isolation, testing method(s), test data, and any corrective action required.
F. Functional Testing of Cathodic Protection Stations 1. Contractor shall perform a function test of each cathodic protection station installed. 2. Functional testing shall demonstrate the following items are functional and ready for Engineer performed energizing and testing: a. AC power service from meter base to rectifier circuit breaker is operational and functional. b. Rectifier produces dc voltage and current output up to the maximum dc current output rating of the rectifier. c. Rectifier controller cards are fully functional and providing control of the rectifier output as specified. d. All impressed current anodes are discharging dc current. e. Remote monitoring system is installed and correctly wired. 3. Upon completion of functional testing, the rectifier shall be left in a de-energized state for Engineer performed System Tests and Inspection. 4. If electrical service is not installed at the time of the functional test, the contractor shall provide a generator with the wattage and voltage output necessary to power the system from the meter base utility connection terminals and complete all testing as defined for functional testing.
3.20 SYSTEM TESTS AND INSPECTION
A. General
1. All testing specified herein shall be performed by the Engineer and shall include: a. Preliminary electrical continuity testing of the full pipeline. b. Cathodic protection system energizing and testing. 2. CONTRACTOR shall correct all construction defects identified during testing. 3. Provide ENGINEER with one week advance notice of completion of cathodic protection work.
B. Electrical Continuity Testing:
1. Preliminary Continuity Test By Engineer a. After the pipeline construction is completed and all test stations have been installed, the ENGINEER shall test all pipelines with joint bonds for electrical continuity using the four-wire lineal pipe resistance test method. b. Test will be conducted with a minimum test current of 15 amperes using a portable rectifier or dc welder. c. An electrically continuous pipeline will be defined as a pipe or section of pipe that has a linear electrical resistance equal to or less than the sum of the resistance of the pipe plus the maximum allowable joint bond resistance for each joint as specified in this section. d. The CONTRACTOR shall locate electrically discontinuous joints at his sole expense as specified herein.
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-30 e. Each discontinuous section of pipe shall be retested by the Engineer after all continuity repairs are completed to demonstrate that the pipeline is electrically continuous. Engineer retesting costs shall be at the Contractor’s expense. 2. Electrical Discontinuity Location: a. CONTRACTOR shall be solely responsible for location and repair of all discontinuous or high resistance joints bonds using a test method determined by the CONTRACTOR. Regardless of test method used to locate discontinuous joints, final acceptance of discontinuous sections shall be determined by the lineal pipe resistance method. b. After all discontinuous or high resistance joint bonds are repaired, the repaired section shall have a resistance less than or equal to the calculated allowable lineal pipe resistance as determined by the initial final continuity testing. c. Existing joint bonds damaged during excavation of the pipe for repairs or temporary wire connections shall be repaired by the CONTRACTOR. d. Existing test stations shall be protected from damage. When damage occurs CONTRACTOR shall complete repairs while the excavation is open. Undisclosed test station damage that requires repairs to be made after backfilling the excavation will be repaired at the CONTRACTOR sole expense.
C. Cathodic Protection System Energizing and Testing:
1. After the installation of the cathodic protection system is completed, the ENGINEER shall energize and adjust the system and ensure proper installation of the cathodic protection system. 2. Test data obtained shall be tabulated and submit in a report of the system operation, test methods, and protection levels. Test data from all testing performed shall be submitted in tabular and electronic form. 3. Energizing and Testing procedures shall, as a minimum, include the following: a. Static pipe-to-soil potentials at each test station on each wire in the test station. b. Test station wire continuity at each test station c. Final electrical continuity of pipeline between each test station. d. ‘ON’ pipe-to-soil potentials at each test station e. Anode current output at each anode test station f. Interference potentials at all crossing metallic pipelines. g. Polarized ‘ON’ potentials after four weeks operation, minimum and three months, maximum. h. Verification of electrical isolation of all insulating joints. i. GPS positions in latitude and longitude format using a WGS 84 datum for all test stations. Locations shall be identified by GPS location, test station type, and street address. Accuracy of GPS positional measurements shall be sub-meter or better.
END OF SECTION
BCA JVWCD IMPRESSED CURRENT CATHODIC PROTECTION CENTRAL PIPELINE PROJECT PAGE 13115-31
SECTION 13675 POLYETHYLENE TANKS
PART 1 – GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall provide polyethylene tanks and accessories, complete and in place, in accordance with the Contract Documents. Tanks may be either constructed of cross- linked polyethylene with a linear-linked liner or constructed of linear-linked polyethylene as recommended by tank manufacturer with regard to chemical compatibility.
B. Unit Responsibility: The Contractor shall assign responsibility for furnishing the tank system as indicated to the tank manufacturer.
1.2 REFERENCE STANDARDS
A. Commercial Standards
ASTM D 618 Standard Practice for Conditioning Plastics for Testing
ASTM D 638 Tensile Properties of Plastics
ASTM D 746 Standard Test Method for Brittleness Temperature of Plastics and Elastomers by Impact
ASTM D 790 Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials
ASTM D 883 Standard Terminology Relating to Plastics
ASTM D 1525 Standard Test Method for Vicat Softening Temperature of Plastics
ASTM D 1693 Standard Test Method for Environmental Stress-Cracking of Ethylene Plastics
ASTM D 1998 Polyethylene Upright Storage Tanks
ASTM D 2765 Standard Test Methods for Determination of Gel Content and Swell Ratio of Cross-linked Ethylene Plastics
ASTM D 2837 Standard Test Method for Obtaining Hydrostatic Design Basis for Thermoplastic Pipe Materials
ASTM F 412 Standard Terminology Relating to Plastic Piping Systems
ANSI B 16.5 Pipe Flanges and Flanged Fittings
BC&A POLYETHYLENE TANKS JVWCD PAGE 13675-1 CENTRAL PIPELINE PROJECT
ARM Low Temperature Impact Resistance (Falling Dart Test Procedure)
NEMA ICS 6 Enclosures for Industrial Control and Systems
1.3 CONTRACTOR SUBMITTALS
A. Furnish shop drawings in accordance with Section 01300 - Contractor Submittals.
B. Shop Drawings shall include, but not be limited to, the following items:
1. Tank manufacturer’s data and dimensions showing locations of all openings, locations of level indicators, seismic support structure and anchoring system details, and location of tanks accessories. Provide information regarding gasket style and material and bolting material. 2. Details on inlet and outlet fittings, access ways, flexible connections, and openings for level indication, vents and other connections. 3. Tank pad requirements for tank seismic anchoring systems or block-out where a full-drain fitting is used. 4. Manufacturer’s written certification signed by a senior company officer stating that the tank design, type, and material is compatible with the indicated chemical to be stored in the tank. Provide data sheet for tank resin material showing compatibility with chemical to be stored under the concentration and temperature conditions expected. 5. Calculations stamped and signed by a registered engineer licensed in the State of Utah. a. Wall thickness and the hoop stress shall be indicated. b. Tank and tank restraint support system. c. Show seismic criteria and calculations using criteria listed in Section 01612 – Seismic Design Criteria.
C. Provide manufacturer warranty and factory test reports as outlined herein.
D. Manufacturer's unloading procedure and installation instructions.
E. Manufacturer’s Qualifications: List of installations documenting manufacturer's qualifications. Include names and telephone numbers for tank installations available for the Engineer to visit.
F. Owner’s Manual: Provide technical manual that outlines recommended installation procedures, fitting installation and adjustment procedures and repair procedures for typical situations including small holes, pinholes, and minor cracks in the tank.
1.4 QUALITY ASSURANCE
A. Manufacturers Qualifications: The tank manufacturer shall have a record of at least 10 installations during the previous 5 years for the tank sizes and for the chemicals indicated in this Contract.
BC&A POLYETHYLENE TANKS JVWCD PAGE 13675-2 CENTRAL PIPELINE PROJECT
B. Special Warranty Requirement: The tank shall be warranted for a period of 3 years after acceptance of project substantial completion to be free of defects in material and workmanship.
C. Certification: After inspecting the installed tank, a representative of the manufacturer shall certify in writing that the tank has been installed in accordance with the manufacturer's recommendations. Certification shall be submitted to the Engineer.
D. Factory Test Report: Submit a factory test report that documents tank nominal capacity and diameter, material, hoop stress design, reviews audit for wall thickness, defines fitting placement and documents visual inspection.
1. Dimensions: Take exterior dimensions with the tank empty, in the vertical position. Outside diameter tolerance, including out-of-roundness, shall be per ASTM D 1998. Fitting placement tolerance shall be 1/2-in vertical and 2 degrees radial. 2. Visual: Inspect for foreign inclusions, air bubbles, pimples, crazing, cracking, and delamination. 3. Wall Thickness a. Tanks 2,000 gal or larger shall be measured for wall thickness by ultrasonic methods at 6-in, 1-ft, 2-ft, and 3-ft up the sidewall at zero and 180 degrees around the circumference from the outlet. b. Tanks smaller than 2000 gal may be tested during a production run and the results reported as representative of each tank in the run. 4. Hydrostatic test: Following fabrication, the tanks, including inlet and outlet fittings, shall be hydraulically tested with water by filling to the brim for a minimum of 4 hours and inspecting for leaks. Following successful testing, the tank shall be emptied and dried prior to shipment. 5. Material Testing: Perform the following tests and include results in the Factory Test Report. a. Low temperature impact test: Condition samples taken from fitting cutouts frozen for 2 hours at minus 40 degrees F. Perform impact tests in accordance with ASTM D 1998. Specimens less than 1/2-in thick shall be tested at 100 ft.-lb. and specimens equal to or thicker than 1/2 -in shall be tested at 200 ft.-lb. b. Degree of cross-linking (applicable to cross link material only): Use Method C of ASTM D 2765 to determine the ortho-xylene insoluble fraction of cross-linked polyethylene. Samples from the inside of the tank 1/8-in deep shall test at no less than 65 percent.
E. An affidavit signed by the tank manufacturer shall be furnished indicating that the factory tests have been performed and the indicated requirements have been met.
PART 2 – PRODUCTS
2.1 GENERAL
A. Tanks shall be constructed of either rotationally-molded high density crosslinked (HDXLPE) or linear-linked (HDLPE) polyethylene as recommended by the tank
BC&A POLYETHYLENE TANKS JVWCD PAGE 13675-3 CENTRAL PIPELINE PROJECT
manufacturer. Cross-linked tanks shall employ a linear linked liner when used to store chemical chlorine solutions such as sodium hypochlorite.
B. Tanks shall be one piece seamless construction, cylindrical in cross-section, vertical in axis; complete with piping outlets, drains, inlets, vents, instrumentation connection hubs and overflows installed or shipped separately with the tank by manufacturer; and anchoring system. Tanks shall be in accordance with ASTM D 1998 unless otherwise indicated. Laminated tanks will not be accepted.
C. Tank outlets shall be integrally molded on the tank and be the same material to allow for full tank draining. Mechanically attached outlets will not be acceptable for use within the operating height of the storage volume.
D. Covered tanks shall be vented, and where indicated, tanks shall be provided with entrance access ways and level monitoring electronics and indicators.
E. Tanks shall be marked to identify the manufacturer, date of manufacture, serial number, capacity, and chemical to be stored.
F. Dimensions and tolerances shall be in accordance with ASTM D 1998. Measurements shall be taken with the tank empty, in the vertical position.
2.2 OPERATING CONDITIONS
A. Chemical storage tanks shall be suitable for the following operating conditions:
CPJN-TK-01 CPJN-TK-02 Equipment number CPJN-JK-03 Chemical stored Hydrofluosilicic Acid Concentration % 25 Specific gravity 1.2 pH 1.5 Maximum chemical temperature Deg. F 85 Minimum chemical temperature Deg. F 50 Minimum indoor air temperature Deg. F 55
2.3 DESIGN CRITERIA
A. The minimum wall thickness of the cylindrical portion at any chemical depth shall be determined by ASTM D 1998 as modified by the following equation. Wall thickness shall be tapered, and no wall shall be less than 0.187-inch thick at the top.
T = 0.433 x ASG x OD x H x OD/2 x SF x SD
Where: T = wall thickness at any depth, in ASG = adjusted specific gravity of chemical (See Note A) H = depth of chemical in tank ft OD = outside diameter of tank, ft
BC&A POLYETHYLENE TANKS JVWCD PAGE 13675-4 CENTRAL PIPELINE PROJECT
SF = service factor based on wall thickness SD = hydrostatic design stress, 600 psi (See Note B)
Note A: The specific gravity of the fluid shall be multiplied by 1.5 to obtain the adjusted specific gravity, ASG. The maximum ASG value shall be 1.9. Note B: The hydrostatic design stress shall be derated for temperatures above 100 deg F according to ASTM D 1998.
B. The minimum wall thickness shall be sufficient to support its own weight in an upright position without external support. Flat areas shall be provided for attachment of large fittings on the cylindrical portion.
C. The top head shall be integrally molded with the cylindrical wall. Its minimum thickness shall equal the thickness of the top of the wall. The top head of tanks 2,000 gal and larger shall provide a minimum of 1,300 square inches of flat surface for pipe nozzle locations.
D. The bottom head shall be integrally molded with the cylindrical wall. Knuckle radius shall be in accordance with ASTM D 1998.
E. Tanks with 2,000 gal capacity or larger shall have at least 3 lifting lugs molded into the top head. Lugs shall be designed for lifting an empty tank.
F. Tie-down lugs may be molded into the top head.
G. Access way: Access ways shall be at least 24-in diameter, non-vented buttress thread style lid.
2.4 MATERIALS OF CONSTRUCTION
A. Materials shall be virgin cross-linked polyethylene as compounded and certified by the manufacturer, be the type indicated in the tank schedule, and shall meet or exceed the following:
1. Mechanical Properties of HDXLPE Tank Material
ASTM Test Value Parameter Unit Method Minimum Density of resin gm/cc D 1505 0.938 – 0.946 Minimum Tensile strength psi (2 D 638 3,000 inches/min) Minimum Elongation at break % (2 D638 Type IV 300 inches/min) specimen Minimum ESCR (100 percent lgepal, hours D 1693 1,000 Condition A, F50) Minimum ESCR (10 percent lgepal, hours D 1693 1,000 Condition A, F50) Maximum Vicat softening temperature Deg. F D 1525 250 Minimum Flexural modulus psi D 790 100,000
BC&A POLYETHYLENE TANKS JVWCD PAGE 13675-5 CENTRAL PIPELINE PROJECT
2. Mechanical Properties of HDLPE Tank Material
ASTM Test Value Parameter Unit Method Minimum Density of resin gm/cc D 1505 0.940 to 0.948 Minimum Tensile strength psi (2 D 638 2,950 inches/min) Minimum Elongation at % (2 D638 Type IV 1,000 break inches/min) specimen Minimum ESCR (100 hours D 1693 550 percent lgepal, Condition A, F50) Minimum ESCR (10 percent hours D 1693 48 lgepal, Condition A, F50) Maximum Vicat softening Deg. F D 1525 235 temperature Minimum Flexural modulus psi D 790 129,000
3. Resin used in the tank shall be by Exxon Mobil Chemicals, or equal, and shall contain ultraviolet stabilizer as recommended by the manufacturer. Where black or white tanks are indicated, the resin shall be compounded black or white.
2.5 TANK SCHEDULE
A. The following polyethylene tanks shall be provided and installed by the CONTRACTOR:
CPJN-TK-01 Equipment No. CPJN-TK-02 CPJN-TK-03 Configuration (see Note 1) Single Wall; CD Single Wall; FLR Material Type HDXLPE or HDLPE HDXLPE with HDLPE Liner or HDLPE Insulation NO NO Nominal diameter, ft 5’-4” 2’-8” Nominal height, ft (see Note 8’-0” 12’-0” 2) Nominal capacity, gallons 1150 90 (see Note 5) Liquid depth, maximum, ft 7’-0” 2’-10” Level Indication Magnetic Flag Type Staff gauge on side of tank gauge on side of tank Access way (see Notes 3 and 4) TM, screwed with gasket N/A Mounting 24 Diameter, inches Exposure indoors indoors Color natural natural
Note 1: CD = closed, domed top CF = closed, flat top
BC&A POLYETHYLENE TANKS JVWCD PAGE 13675-6 CENTRAL PIPELINE PROJECT
OIF = open, internal flange OEF = open, external flange FLR = flat lid, removable FLH = flat lid, hinged
Note 2: Nominal height of domed top tanks is the dimension measured along the straight cylindrical portion of the tank and does not include the rounded top.
Note 3: TM = top mount TSM = top and side mount
Note 4: Unless otherwise indicated, access ways shall be integrally molded with the tank.
Note 5: Nominal volume shall be calculated based on the straight cylindrical side of the tank.
2.6 FITTINGS
A. Tank fittings shall be according to the fitting schedule below and oriented as shown on the drawings in the Contract Documents. Gasket material shall be EPDM. Fittings shall be compatible with the chemical stored, be bolted double flanged fittings, Schedule 80, or threaded bulkhead type. Threaded fittings shall use American Standard Pipe Threads. No metals shall be exposed to tank contents. If tanks are insulated, fittings shall be installed at the factory prior to application of the insulation.
Tanks T-420A and T-420B Fitting Type (See Note 4) and Size Port Description Diameter (inches) Type of Fitting Fill (top mounted) 2” TB Overflow 2” BF-H Tank drain/outlet 3” IMF (flush with bottom of tank) U-Vent (high point of 3” TB tank) Level indication (top 6” BF-H mounted)
Note 4: Refer to Drawings for fitting size and location. Abbreviations for fittings are: TB: Threaded bulkhead fitting BF-H: Bolted flange fitting with Hastelloy-C studs and polyethylene encapsulated heads. IMF: Integrally molded flanged.
B. Bulkhead fittings shall be constructed of PVC, PP, or other material compatible with the chemical stored. Gaskets shall be a minimum of 1/4-in thickness and be constructed of 40
BC&A POLYETHYLENE TANKS JVWCD PAGE 13675-7 CENTRAL PIPELINE PROJECT
to 50 durometer EPDM, 60 to 70 durometer Viton, or material compatible with the chemical in the tank.
C. Bolted flange fittings shall be constructed with two 150 psi flanges, two 150 psi flange gaskets, and the correct number and size of all-thread bolts recommended by the flange manufacturer. Flanges shall be constructed of PVC type 1, grade 1. Gaskets shall be min 1/4-in thick, constructed of 40 to 50 durometer EPDM, 60 to 70 durometer Viton, or material compatible with the chemical in the tank. There shall be minimum 4 full-thread bolts. Bolt heads may be gasket-flanged or may be encapsulated in a type of polyethylene compatible with the chemical stored. If encapsulated, the bolt head shall not contact the fluid in the tank and shall cover the head plus 1/4-in of threads away from the head. Polyethylene shall be color coded to identify the bolt metal underneath. Encapsulated heads shall have a gasket to provide a sealing surface against the inner flange. Bolt holes shall straddle the principal centerline of the tank in accordance with ASME B16.5
1. Integrally Molded Fittings (IMF). These fittings shall be an integral part of the tank and provide complete drainage of liquid through the sidewall of a flat bottom tank. The attachment shall be constructed from a Schedule 80 PVC, stainless steel, or compatible material and be standard at 2-, 3-, 4- or 6-in with inside diameter depending on the tank size.
D. Down Pipes and Fill Pipes: Down pipes and fill pipes shall be supported at 5-ft max intervals with support from standard bulkhead fitting tank attachments or welded PE supports. Down pipes and fill pipes shall be PVC or material compatible with the chemical stored.
E. U-Vents: Each tank must be vented for the material and flow and withdrawal rates expected. Vents should comply with OSHA 1910.106(F)(iii)(2)(IV)(9) or shall be as large as the filling or withdrawal connection, whichever is larger, but in no case less than 1-in nominal inside diameter. U-vents shall be sized by the tank manufacturer and be furnished complete with insect screen. U-vents shall be constructed of PVC or material compatible with the chemical stored.
F. Flange Adapters: Adapters may be used to adapt threaded or socket weld fitting components to 150-psi flange connections. Adapters shall be of material compatible with the chemical stored.
G. Ladders: Ladders shall be constructed of FRP. Ladders must be designed to OSHA standard 2206; 1910.27. Ladders shall be mounted to the tank in such a way that tank expansion and contraction are not restricted. Top ladder mounts shall be connected to the tank as appropriate.
E. Provide flexible couplers for each tank connection for each tank supplied to this project. All tank fitting attachments shall be equipped with flexible couplers or other movement provisions provided by the tank manufacturer. The tank will deflect based upon tank loading, chemical temperature, and storage time duration. Tank piping flexible couplers shall be designed to allow 4% design movement. Movement shall be considered to
BC&A POLYETHYLENE TANKS JVWCD PAGE 13675-8 CENTRAL PIPELINE PROJECT
occur both outward in tank radius and downward in fitting elevation from the neutral tank fitting placement.
2.7 TANK SEISMIC RESTRAINT SYSTEM
A. The tank shall be restrained as indicated on the Contract Drawings. Tank Supplier shall design and supply restraint requirements in accordance with the 2006 International Building Code using criteria listed in Section 01612 – Seismic Design Criteria. Stamped calculations and or drawings by a Professional Engineer licensed in the State of Utah will be required.
B. Metal components, including tension ring, clamps and anchor rods, shall be constructed of materials suitable for use with the chemical application.
C. The Contractor shall coordinate the requirements for the seismic restraint of the chemical daytank (CPJN-TK-03) with the requirements of the tank scale such that the operational integrity and accuracy of the tank scale is not jeopardized.
2.8 TANK ACCESSORIES
A. Signage: Each tank shall be clearly marked with hazardous material warning signs, 10- inches by 14-inches in size. Each sign shall have the word "DANGER", the name of the chemical stored, and MSDS data, printed in large block letters and mounted directly adjacent to the tank outlet and tank inlet. Each entry access way shall be provided with a sign reading "DANGER--CONFINED SPACE--HAZARDOUS ATMOSPHERE". Signs shall comply with Section 10425 - Signs and the requirements herein.
B. Primary level indication shall be a radar type device, as specified in Section 17106 – Level – Radar, provided and installed by the Contractor as part of the plant instrumentation and control system. Contractor shall coordinate with the tank manufacturer the flange interface with the ultrasonic level device.
C. Visual Level Indication: The Contractor shall provide and install a magnetic flag type level indication column. The materials of construction shall be suitable for use with Hydrofluorosilicic Acid (25% concentration).
1. Manufacturer: John C Ernst, Co. Model 048HC
2.9 MANUFACTURERS, OR EQUAL
A. Poly Processing Company
B. Snyder Industries, Inc.
PART 3 – EXECUTION
3.1 DELIVERY, STORAGE, AND HANDLING
A. The tank shall be shipped upright or lying down on their sides with blocks and slings to keep them from moving and all sharp objects on trailers shall be removed.
BC&A POLYETHYLENE TANKS JVWCD PAGE 13675-9 CENTRAL PIPELINE PROJECT
B. All fittings shall be installed and, if necessary, removed for shipping and shipped separately unless otherwise noted by the contractor.
C. Upon arrival at the destination, inspect the tank(s) and accessories for damage in transit. If damage has occurred, the Tank Supplier shall be notified immediately.
3.2 INSTALLATION
A. Installation shall be in accordance with the manufacturer's recommendations.
B. After installation of each tank and all fittings, each tank shall be water tested by filling the entire tank with water and monitoring the tank as well as all fittings connections for at least 24 hours. Any leaks shall be corrected prior to acceptance. Following successful field testing, the tank shall be completely emptied and dried.
3.3 FIELD TESTING
A. After installation of tank and connections, the tank shall be water tested by filling the entire tank with water and monitoring the tank and connections for at least 24 hours. Leaks shall be corrected prior to acceptance. Following successful field testing, the tank shall be completely emptied and dried.
END OF SECTION
BC&A POLYETHYLENE TANKS JVWCD PAGE 13675-10 CENTRAL PIPELINE PROJECT
DIVISION 15 MECHANICAL
SECTION 15000 PIPING, GENERAL
PART 1 – GENERAL
1.1. THE REQUIREMENT
A. The Contractor shall furnish and install all piping systems shown and specified, in accordance with the requirements of the Contract Documents. Each system shall be complete with all necessary fittings, hangers, supports, anchors, seismic restraints, expansion joints, flexible connectors, valves, accessories, heat tracing, insulation, lining and coating, testing, disinfection, excavation, backfill and encasement, to provide a functional installation.
B. The piping shown is intended to define the general layout, configuration, routing, method of support, pipe size, and pipe type. The mechanical drawings are not pipe construction or fabrication drawings. It is the Contractor's responsibility to develop the details necessary to construct all mechanical piping systems, to accommodate the specific equipment provided, and to provide and install all spools, spacers, adapters, connectors, etc., for a complete and functional system.
1.2. REFERENCE SPECIFICATIONS, CODES, AND STANDARDS
A. Commercial Standards
ANSI/ASME B1.20.1 Pipe Threads, General Purpose (inch)
ANSI B16.5 Pipe Flanges and Flanged Fittings, Steel Nickel Alloy and other Special Alloys
ANSI/AWWA C207 Steel Pipe Flanges for Water Works Service, Sizes 4 in through 144 in.
ANSI/AWWA C606 Grooved and Shouldered Joints
ANSI/AWS D1.1 Structural Welding Code
ASTM A 307 Specification for Carbon Steel Bolts and Studs, 6,000 psi Tensile
ASTM A 325 Specification for High-Strength Bolts for Structural Steel Joints
ASTM D 792 Test Methods for Specific Gravity and Density of Plastics by Displacement
ASTM D 2000 Classification System for Rubber Products in Automotive Applications
BC&A PIPING, GENERAL JVWCD PAGE 15000-1 CENTRAL PIPELINE PROJECT 1.3. Contractor SUBMITTALS
A. Submit complete shop drawings and certificates, test reports, affidavits of compliance, of all piping systems, in accordance with the requirements in Section 01300 – Contractor Submittals, and as indicated in the individual piping sections. The shop drawings shall include all necessary dimensions and details on pipe joints, fittings, fitting specials, valves, appurtenances, design calculations, and material lists. The submittals shall include detailed layout, spool, or fabrication drawings which show all pipe spools, spacers, adapters, connectors, fittings, and pipe supports and seismic restraints necessary to accommodate the equipment and valves provided in a complete and functional system.
B. All expenses incurred in making samples for certification of tests shall be borne by the Contractor at no increased cost to the Owner.
C. Submit as part of the shop drawings a statement from the pipe fabricator certifying that all pipes will be fabricated subject to a recognized Quality Control Program. An outline of the program shall be submitted to the Engineer for review prior to the fabrication of any pipe.
1.4. QUALITY ASSURANCE
A. Inspection: All pipe shall be subject to inspection at the place of manufacture. During the manufacture of the pipe, the Engineer shall be given access to all areas where manufacturing is in progress and shall be permitted to make all inspections necessary to confirm compliance with the Specifications.
B. Tests: Except where otherwise indicated, all materials used in the manufacture of the pipe shall be tested in accordance with the applicable specifications and standards. Welds shall be tested as indicated. Perform all tests at no additional cost to the Owner.
C. Welding Requirements: All welding procedures used to fabricate pipe shall be prequalified under the provisions of ANSI/AWS D1.1. Welding procedures shall be required for, but not necessarily limited to, longitudinal and girth or spiral welds for pipe cylinders, spigot and bell ring attachments, reinforcing plates and ring flange welds, and plates for lug connections.
D. Welder Qualifications: All welding shall be done by skilled welders, welding operators, and tackers who have had adequate experience in the methods and materials to be used. Welders shall be qualified under the provisions of ANSI/AWS D1.1 by an independent local, approved testing agency not more than 6 months prior to commencing Work on the pipeline. Machines and electrodes similar to those used in the Work shall be used in qualification tests. Furnish all material and bear the expense of qualifying welders at no increased cost to the Owner.
1.5. MANUFACTURER'S SERVICE REPRESENTATIVE
A. Where the assistance of a manufacturer's service representative is advisable, in order to obtain perfect pipe joints, supports, or special connections, furnish such assistance at no additional cost to the Owner. BC&A PIPING, GENERAL JVWCD PAGE 15000-2 CENTRAL PIPELINE PROJECT
1.6. MATERIAL DELIVERY, STORAGE, AND PROTECTION
A. All piping materials, fittings, valves, and accessories shall be delivered in a clean and undamaged condition and stored off the ground, to provide protection against oxidation caused by ground contact. All defective or damaged materials shall be replaced with new materials.
1.7. CLEANUP
A. After completion of the Work, all remaining pipe cuttings, joining and wrapping materials, and other scattered debris, shall be removed from the site. The entire piping system shall be handed over in a clean and functional condition.
PART 2 – PRODUCTS
2.1 GENERAL
A. All pipes, fittings, and appurtenances shall be furnished in accordance with the requirements of the applicable Sections of Divisions 2 and 15 and this Section.
B. Miscellaneous Small Pipes: Miscellaneous small pipes and fittings shall be provided by the Contractor in accordance with the requirements of Section 15010 - Mill Piping - Exposed and Buried and this Section.
C. Pipe Supports: All pipes shall be adequately supported in accordance with the requirements of Section 15006 - Pipe Supports, and as indicated.
D. Lining: All requirements pertaining to thickness, applications, and curing of pipe lining, are in accordance with the requirements of the applicable Sections of Division 2 and 9, unless otherwise indicated.
E. Coating: All requirements pertaining to thickness, application, and curing of pipe coating, are in accordance with the requirements of the applicable Sections of Division 2, unless otherwise indicated. Pipes above ground or in structures shall be field-painted in accordance with Section 09910 - Pipeline Coating.
F. Pressure Rating: All piping systems shall be designed for the maximum expected pressure as defined in Section 02643 - Water Pipeline Testing and Disinfection, or as indicated on the piping schedule.
G. Grooved Piping Systems: Piping systems with grooved joints and fittings may be provided, if approved by the Engineer, in lieu of screwed, flanged, welded, or mechanical joint systems for steel and ductile iron yard piping above and below ground within the property limits of pump stations, and similar installations. All grooved couplings on buried piping must be bonded. To assure uniform and compatible piping components, all grooved fittings, couplings, and valves shall be from the same manufacturer. The Contractor shall make the coupling manufacturer responsible for the selection of the correct style of coupling and gasket for each individual location.
BC&A PIPING, GENERAL JVWCD PAGE 15000-3 CENTRAL PIPELINE PROJECT 2.2 PIPE FLANGES
A. Flanges: Where the design pressure is 150 psi or less, flanges shall conform to either ANSI/AWWA C207 Class D or ANSI B16.5 150-pound class. Where the design pressure is greater than 150 psi, up to a maximum of 275 psi, flanges shall conform to either ANSI/AWWA C207 Class E, Class F, or ANSI B16.5 150-pound class. However, AWWA flanges shall not be exposed to test pressures greater than 125 percent of rated capacity. For higher test pressures, the next higher rated AWWA flange or an ANSI- rated flange shall be selected. Where the design pressure is greater than 275 psi up to a maximum of 700 psi, flanges shall conform to ANSI B16.5 300-pound class. Flanges shall have flat faces and shall be attached with bolt holes straddling the vertical axis of the pipe unless otherwise shown. Attachment of the flanges to the pipe shall conform to the applicable requirements of ANSI/AWWA C207. Flanges for miscellaneous small pipes shall be in accordance with the standards specified for these pipes.
B. Blind Flanges: Blind flanges shall be in accordance with ANSI/AWWA C207, or with the standards for miscellaneous small pipes. All blind flanges for pipe sizes 12 inches and over shall be provided with lifting eyes in form of welded or screwed eye bolts.
C. Flange Coating: All machined faces of metal blind flanges and pipe flanges shall be coated with a temporary rust-inhibitive coating to protect the metal until the installation is completed.
D. Flange Bolts: Contractor shall supply all bolts and nuts in conformance with Section 05500 - Miscellaneous Metalwork. Studs and bolts shall extend through the nuts a minimum of 1/4 inch. All-thread studs shall be used on all valve flange connections, where space restrictions preclude the use of regular bolts.
E. Insulating Flanges: Insulated flanges shall have bolt holes 1/4 inch diameter greater than the bolt diameter.
F. Insulating Flange Sets: Insulating flange sets shall be provided by the Contractor where shown. Each insulating flange set shall consist of an insulating gasket, insulating sleeves and washers and a steel washer. Insulating sleeves and washers shall be one piece when flange bolt diameter is 1-1/2 inches or smaller and shall be made of acetal resin. For bolt diameters larger than 1-1/2 inches, insulating sleeves and washers shall be two-piece and shall be made of polyethylene or phenolic. Steel washers shall be in accordance with ASTM A 325. Insulating gaskets shall be full-face.
G. Insulating Flange Manufacturers, or Equal
1. JM Red Devil, Type E 2. Maloney Pipeline Products Co., Houston 3. PSI Products, Inc., Burbank, California.
H. Flange Gaskets: Contractor shall provide flange gaskets for all pipe flanges. Gaskets for flanged joints shall be full-faced, 1/16-inch thick compressed sheets of asbestos-free aramid fiber base, with nitrile binder and nonstick coating, suitable for temperatures to 700 degrees F, a pH of 1 to 11, and pressures to 1,000 psig. Blind flanges shall have gaskets covering the entire inside face of the blind flange and shall be cemented to the blind flange. Ring gaskets shall not be permitted. BC&A PIPING, GENERAL JVWCD PAGE 15000-4 CENTRAL PIPELINE PROJECT
I. Flange Gasket Manufacturers, or Equal
1. John Crane, Style 2160. 2. Garlock, Style 3000.
2.3 THREADED INSULATING CONNECTIONS
A. General: Threaded insulating bushings, unions, or couplings, as appropriate, shall be used for joining threaded pipes of dissimilar metals and for piping systems where corrosion control and cathodic protection are involved.
B. Materials: Threaded insulating connections shall be of nylon, Teflon, polycarbonate, polyethylene, or other nonconductive materials, and shall have ratings and properties to suit the service and loading conditions.
2.4 MECHANICAL-TYPE COUPLINGS (GROOVED OR BANDED PIPE)
C. Construction: Cast mechanical-type couplings shall be provided where shown. The couplings shall conform to the requirements of ANSI/AWWA C606. Bolts and nuts shall conform to the requirements of Section 05500 - Miscellaneous Metalwork. All gaskets for mechanical-type couplings shall be compatible with the piping service and fluid utilized, in accordance with the coupling manufacturer's recommendations. The wall thickness of all grooved piping shall conform with the coupling manufacturer's recommendations to suit the highest expected pressure. To avoid stress on equipment, all equipment connections shall have rigid-grooved couplings, or harness sets in sizes where rigid couplings are not available, unless thrust restraint is provided by other means. The Contractor shall have the coupling Manufacturer's service representative verify the correct choice and application of all couplings and gaskets, and the workmanship, to assure a correct installation.
D. Couplings for Steel Pipe, Manufacturers, or Equal
1. Victaulic Style 44 with Type D Heavy Duty Grooved Adaptor Ends. 2. Brico Industries, A Victaulic Company (Depend-O-Lok FXF Type 2)
E. Couplings for PVC Pipe, Manufacturers, or Equal
1. Gustin-Bacon. 2. Victaulic Style 775. Note: Couplings for PVC pipe shall be furnished with radius cut or standard roll grooved pipe ends. Grooved end couplings shall be used on PVC pipe only for Schedule 80 vent piping at the vaults. Grooved end couplings shall not be used for PVC C905 water pipe.
2.5 SLEEVE-TYPE COUPLINGS
F. Construction: Sleeve-type couplings shall be provided where indicated, in accordance with ANSI/AWWA C219 unless otherwise indicated, and shall be of steel with steel bolts, without pipe stop, and shall be of sizes to fit the pipe and fittings. The middle ring shall be not less than 1/4 inch in thickness and shall be either 5 or 7 inches long for sizes up BC&A PIPING, GENERAL JVWCD PAGE 15000-5 CENTRAL PIPELINE PROJECT to and including 30 inches and 10 inches long for sizes greater than 30 inches, for standard steel couplings, and 16 inches long for long-sleeve couplings. The followers shall be single-piece contoured mill section welded and cold-expanded as required for the middle rings. They shall be of sufficient strength to accommodate the number of bolts necessary to obtain adequate gasket pressures without excessive rolling. The shape of the follower shall be of such design as to provide positive confinement of the gasket. Bolts and nuts shall conform to the requirements of Section 05500 - Miscellaneous Metalwork. Buried sleeve-type couplings shall be epoxy-coated at the factory.
G. Pipe Preparation: The ends of the pipe, where indicated, shall be prepared for flexible steel couplings. Plain ends for use with couplings shall be smooth and round for a distance of 12 inches from the ends of the pipe, with outside diameter not more than 1/64 inch smaller than the nominal outside diameter of the pipe. The middle ring shall be tested by cold-expanding a minimum of one percent beyond the yield point, to proof- test the weld to the strength of the parent metal. The weld of the middle ring shall be subjected to air test for porosity.
H. Gaskets: Gaskets for sleeve-type couplings shall be rubber-compound material that will not deteriorate from age or exposure to air under normal storage or use conditions. Gaskets for wastewater and sewerage applications shall be Buna "N," grade 60, or equivalent suitable elastomer.
1. The rubber in the gasket shall meet the following specifications: a. Color - Jet Black. b. Surface - Nonblooming. c. Durometer Hardness - 74 " 5. d. Tensile Strength - 1,000 psi Minimum. e. Elongation - 175 percent Minimum. 2. The gaskets shall be immune to attack by impurities normally found in water or wastewater. All gaskets shall meet the requirements of ASTM D 2000, AA709Z, meeting Suffix B13 Grade 3, except as noted above. All gaskets shall be compatible with the piping service and fluid utilized.
I. Insulating Couplings: Where insulating couplings are required, both ends of the coupling shall have a wedge-shaped gasket which assembles over a rubber sleeve of an insulating compound in order to obtain insulation of all coupling metal parts from the pipe.
J. Restrained Joints: All sleeve-type couplings on pressure lines shall be harnessed unless thrust restraint is provided by other means. Harnesses shall be in accordance with the requirements of the appropriate reference standard, or as shown.
K. Manufacturers, or Equal
1. Dresser, Style 38. 2. Ford Meter Box Co., Inc., Style FC1 or FC3. 3. Smith-Blair, Style 411. 4. Baker, Series 200
BC&A PIPING, GENERAL JVWCD PAGE 15000-6 CENTRAL PIPELINE PROJECT 2.6 FLANGED END CONNECTORS
A. Flanged coupling adapters, shall be in accordance with AWWA C219.
B. Dismantling joints for connecting flanged pipe shall be AWWA C219 compliant. Provide studs and nuts to seal gasket separate and independent from tie-bar restraint system.
C. All dismantling joints shall be the restrained type per AWWA M-11. Tie-bar restraint system shall conform to ASTM A193-B7 per AWWA M-11 and be designed to withstand the test pressure shown on the Drawings.
D. All dismantling joints shall use standard flanges in accordance with AWWA C207. The thickness of the dismantling joint flanges shall be equal to or greater than the class of flange that is connected to as required by the test pressure as shown on the drawings. Buried flanges shall be wrapped with petroleum was tape per AWWA C217.
E. Manufacturers, or Equal
1. Smith-Blair, Style 972 or 975 2. Romac, Series DJ400 3. Baker
2.7 PIPE THREADS
L. All pipe threads shall be in accordance with ANSI/ASME B1.20.1.
PART 3 – EXECUTION
3.1 GENERAL
A. All pipes, fittings, and appurtenances shall be installed in accordance with the requirements of the applicable Sections of Divisions 2 and 15. The lining manufacturer shall take full responsibility for the complete, final product and its application. All pipe ends and joints at screwed flanges shall be epoxy-coated, to assure continuous protection.
B. Where core drilling is required for pipes passing through existing concrete, core drilling locations shall be determined by radiograph of concrete construction to avoid damage to embedded raceways and rebars.
M. Flanges shall be installed at least 6-inches from a wall. Fittings shall be installed with sufficient clearance for maintenance and removal and reinstallation.
END OF SECTION
BC&A PIPING, GENERAL JVWCD PAGE 15000-7 CENTRAL PIPELINE PROJECT
SECTION 15005 PIPING IDENTIFICATION SYSTEM
PART 1 – GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall provide identification for all exposed piping and valves, in accord- ance with the requirements of the Contract Documents.
1.2 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS
A. Commercial Standards
ANSI A13.1 Scheme for the Identification of Piping Systems
1.3 CONTRACTOR SUBMITTALS
A. All submittals shall be in strict accordance with the requirements of Section 01300 - Con- tractor Submittals.
B. Submit samples of all types of identification devices to be used in the Work.
C. Submit a list of suggested wording for all valve tags prior to fabrication.
PART 2 – PRODUCTS
2.1 IDENTIFICATION OF PIPING
A. Identification of all exposed pipe shall be accomplished in accordance with the Owner’s standard, and where no standard exists, in accordance with the following: by color- coding with bands and by lettering as specified in Part 3, herein, and in Section 09900 – Coatings and Painting. Color bands shall either be painted directly upon the pipe or shall be pressure-sensitive adhesive-backed vinyl cloth or plastic tape.
B. Each pipe identification shall consist of two color-coded bands OR color-coded coating, a printed label identifying the name of the pipe, and a flow arrow to indicate direction of flow in the pipe. All labels shall be preprinted on pressure-sensitive adhesive-backed vi- nyl cloth or plastic tape. Arrows shall be die-cut of the same type of material as the la- bels or integral to the preprinted label.
C. Letter sizes and colors for lettering, arrows, and background shall conform to ANSI A13.1.
D. Preprinted identification devices shall be as manufactured by Marking Services Inc.; W.H. Brady Co.; Seton Nameplate Corp., or equal.
BC&A PIPING IDENTIFICATION JVWCD PAGE 15005-1 CENTRAL PIPLINE PROJECT 2.2 EXISTING IDENTIFICATION SYSTEMS
A. In installations where existing piping identification systems have been established, con- tinue to use the existing system. Where existing identification systems are incomplete, utilize the existing system as far as practical and supplement with the specified system. The objective is to fully identify all new piping, valves, and appurtenances to the level specified herein.
2.3 IDENTIFICATION OF VALVES AND SHORT PIPE LENGTHS
A. Identifying devices for valves and the sections of pipe that are too short to be identified with color bands, lettered labels, and arrows shall be identified with metal or plastic tags as indicated.
B. Metal tags shall be of type 304L or 316L stainless steel with embossed lettering. Plastic tags shall be of solid black plastic laminate with white embossed letters. All tags shall be designed to be firmly attached to the valves or short pipes or to the structure immediate- ly adjacent to such valves or short pipes.
PART 3 – EXECUTION
3.1 GENERAL
A. All labels and identification tags shall be installed in accordance with the manufacturer's printed instructions, and shall be neat and uniform in appearance. All such tags or la- bels shall be readily visible from all normal working locations.
3.2 VALVE TAGS
A. Valve tags shall be permanently attached to the valve or structure by means of 2 stain- less steel bolts or screws or stainless steel wire.
B. The wording on the valve tags shall describe the exact function of each valve, e.g., "HWR-BALANCING," "CLS THROTTLING", " PUMP SHUT-OFF," etc.
C. Tags attached to valves must be place in such a way that the operation of the valve is not hindered or jeopardized.
3.3 PIPE IDENTIFICATION
A. Each pipe shall be identified at intervals of 20 feet, and at least one time in each room. Piping shall also be identified at a point approximately within 2 feet of all turns, ells, valves, and on the upstream side of all distribution fittings or branches. Sections of pipe that are too short to be identified with color bands, lettered labels, and directional arrows shall be tagged and identified similar to valves.
B. Pipe identification shall consist of these elements, i.e., 2 color bands OR color coating as specified, a lettered label, and a directional label. If bands are used. The bands shall be arranged so that the lettered label and the directional arrow are placed between the 2 bands.
BC&A PIPING IDENTIFICATION JVWCD PAGE 15005-2 CENTRAL PIPLINE PROJECT 3.4 IDENTIFICATION SCHEDULE
A. Application of identifying devices shall conform to the following color codes where no colors are indicated in the Owner’s standard. Fluid Identification Abbreviation Function and Identification Color
AV Air Vent
D Drain
FA Fluoride orange
HW Domestic hot water green
NG Natural gas yellow
PW Potable water green
SMP Sample lines blue
SPD Sump pump discharge blue
TW Tepid Water green
UW Utility Water blue
V Vent Orange
END OF SECTION
BC&A PIPING IDENTIFICATION JVWCD PAGE 15005-3 CENTRAL PIPLINE PROJECT
SECTION 15006 PIPE SUPPORTS
PART 1 – GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall provide pipe supports, seismic restraints, hangers, guides, and anchors, complete, in accordance with the Contract Documents.
1.2 CONTRACTOR SUBMITTALS
B. General: Submittals shall be in accordance with Section 01300 - Contractor Submittals.
C. Shop Drawings: Shop drawings shall include the following information:
1. Drawings of pipe supports, restraints, hangers, anchors, and guides 2. Calculations for special supports and anchors.
PART 2 – PRODUCTS
2.1 GENERAL REQUIREMENTS
A. Code Compliance: Piping systems and pipe connections to equipment shall be properly anchored and supported to prevent undue deflection, vibration, dislocation due to seismic events and line pressures, and stresses on piping, equipment, and structures. Supports and parts thereof shall conform to the requirements of ASME B31.1 – Power Piping, except as supplemented or modified below. Supports for plumbing piping shall be in accordance with the latest edition of the applicable plumbing code or local administration requirements.
B. Structural Members: Wherever possible, pipes shall be supported from structural members. Where it is necessary to frame structural members between existing members, such supplementary members shall be provided at no additional cost to the Owner. All supplementary members shall be in accordance with the requirements of the building code and the American Institute of Steel Construction and shall be acceptable to the Engineer.
C. Pipe Hangers: Pipe hangers shall be capable of supporting the pipe in all conditions of operation, allowing free expansion and contraction of the piping, and preventing excessive stress on equipment. Hangers shall have a means of vertical adjustment after erection. Hangers shall be designed to prevent becoming disengaged by any movement of the supported pipe. Hangers subject to shock, seismic disturbances, or thrust imposed by the actuation of safety valves, shall include hydraulic shock suppressors. Hanger rods shall be subject to tensile loading only.
D. Hangers Subject to Horizontal Movements: At hanger locations where lateral or axial movement is anticipated, suitable linkage shall be provided to permit such movement. Where horizontal pipe movement is greater than 1/2-inch, or where the hanger rod deflection from the vertical is greater than 4 degrees from the cold to the hot position of
BC&A PIPE SUPPORTS JVWCD PAGE 15006-1 CENTRAL PIPLINE PROJECT the pipe, the hanger rod and structural attachment shall be offset in such a manner that the rod is vertical in the hot position.
E. Spring-Type Hangers: Spring-type pipe hangers shall be provided for piping subject to vibration or vertical expansion and contraction, such as engine exhausts and similar piping. Spring-type hangers shall be sized to the manufacturer's printed recommendations and the loading conditions encountered. Variable spring supports shall be provided with means to limit misalignment, buckling, eccentric loading, or to prevent overstressing of the spring, and with means to indicate at all times the compression of the spring. Supports shall be capable of accommodating at least four times the maximum travel due to thermal expansion.
F. Thermal Expansion: Wherever expansion and contraction of piping is expected, a sufficient number of expansion loops or joints shall be provided, together with the necessary rolling or sliding supports, anchors, guides, pivots, and restraints permitting the piping to expand and contract freely in directions away from the anchored points. Components shall be structurally suitable to withstand loads imposed.
G. Heat Transmission: Supports, hangers, anchors, and guides shall be so designed and insulated, that excessive heat will not be transmitted to the structure or to other equipment.
H. Riser Supports: Where practical, risers shall be supported on each floor with riser clamps and lugs, independent of the connected horizontal piping.
I. Freestanding Piping: Free-standing pipe connections to equipment such as chemical feeders and pumps shall be firmly attached to steel frames fabricated from angles, channels, or I-beams anchored to the structure. Exterior, free-standing overhead piping shall be supported on fabricated pipe stands consisting of pipe columns anchored to concrete footings, with horizontal, welded steel angles and U-bolts or clamps securing the pipes.
J. Materials of Construction:
1. General: Pipe support assemblies, including framing, hardware, and anchors, shall be steel construction, galvanized after fabrication, unless otherwise indicated. 2. Submerged Supports: Submerged piping, as well as piping, conduits, and equipment in hydraulic structures within 24 inches of the water level, shall be supported with support, assemblies, including framing, hardware, and anchors, constructed of Type 316 stainless steel, unless otherwise indicated. 3. Corrosive: Piping in chemical and corrosive areas shall be supported with support assemblies, including framing, hardware, and anchors, in compliance with the requirements of Section 15007 – Non-Metallic Pipe Support System, unless otherwise indicated.
K. Point Loads: Any meters, valves, heavy equipment, and other point loads on PVC, FRP, and other plastic pipes, shall be supported on both sides, according to manufacturer's recommendations to avoid undue pipe stresses and failures. To avoid point loads, all supports on PVC, FRP, and other plastic piping shall be equipped with extra wide pipe saddles or galvanized steel shields.
BC&A PIPE SUPPORTS JVWCD PAGE 15006-2 CENTRAL PIPLINE PROJECT L. Noise Reduction: To reduce transmission of noise in piping systems, copper tubes in buildings and structures shall be wrapped with a 2-inch wide strip of rubber fabric or similar, suitable material at each pipe support, bracket, clip, or hanger.
2.2 SUPPORT SPACING
A. Supports for piping with the longitudinal axis in approximately a horizontal position shall be spaced to prevent excessive sag, bending, and shear stresses in the piping, with special consideration given where components such as flanges and valves impose concentrated loads. Pipe support spacing shall not exceed the maximum spans in the tables below. For temperatures other than ambient temperatures, or those listed, and for other piping materials or wall thicknesses, the pipe support spacings shall be modified in accordance with the pipe manufacturer's recommendations. Vertical supports shall be provided to prevent the pipe from being overstressed from the combination of all loading effects.
1. Support Spacing for Schedule 40 and Schedule 80 Steel Pipe
Nominal Pipe Diameter Maximum Span
(inches) (feet) 1/2 6 3/4 and 1 8 1-1/4 to 2 10 3 12 4 14 6 17 8 and 10 19 12 and 14 23 16 and 18 25 20 and Greater 30
2. Support Spacing for Welded Fabricated Steel Pipe
BC&A PIPE SUPPORTS JVWCD PAGE 15006-3 CENTRAL PIPLINE PROJECT
Maximum Spans for Pipe Supported in Minimum 120 degree contact saddles (feet) Nominal Pipe Diameter (inches) 3/16 1/4 5/16 3/8 7/16 1/2 5/8 3/4 7/8 1 24 33 37 41 43 45 47 26 34 38 41 44 46 48 28 34 38 41 44 47 49 30 34 38 42 45 48 49 32 34 39 42 45 48 50 34 35 39 42 46 48 50 36 35 39 43 46 49 51 55 38 35 39 43 46 49 51 55 40 35 40 43 47 49 52 56 42 -- 40 43 47 50 52 56 45 -- 40 44 47 50 53 57 48 -- 40 44 47 50 53 58 61 51 -- 41 44 48 51 53 58 62 54 -- 41 44 48 51 54 58 62 57 -- 41 44 48 51 54 59 63 60 -- 41 45 48 52 54 59 63 67 70 63 -- 41 45 49 52 55 60 64 67 71 66 -- 41 45 49 52 55 60 64 68 71 72 -- 41 45 49 52 55 61 65 69 72 78 -- 41 45 49 53 56 61 66 69 73 84 -- 41 46 50 53 56 62 66 70 74 90 -- 41 46 50 53 56 62 67 71 74 96 -- 42 46 50 54 57 62 67 71 75
3. For steel pipe sizes not presented in this table, the support spacing shall be designed so that the stress on the pipe does not exceed 5,000 psi. Maximum deflection of pipe shall be limited to 1/360th of the span and shall be calculated by using the formula:
7500tD L = 32t + D
Where: t = Thickness (inches) D = Diameter (inches) L = Maximum span (feet)
BC&A PIPE SUPPORTS JVWCD PAGE 15006-4 CENTRAL PIPLINE PROJECT
4. Support Spacing for Ductile-Iron Pipe: Nominal Pipe Diameter Maximum Span (inches) (feet)
All Diameters Two supports per pipe length or 10 feet (one of the 2 supports located at joint)
5. Support Spacing for Copper Tubing: Nominal Pipe Diameter Maximum Span (inches) (feet)
1/2 to 1-1/2 6 2 to 4 10 6 and Greater 12
6. Support Spacing for Schedule 80 PVC Pipe: Maximum Span Nominal Pipe Diameter (at 100 degrees F) (inches) (feet)
1/2 4 3/4 4.5 1 5 1-1/4 5.5 1-1/2 5.75 2 6.25 3 7.5 4 8.25 6 10 8 11 10 12.25 12 13.25
BC&A PIPE SUPPORTS JVWCD PAGE 15006-5 CENTRAL PIPLINE PROJECT
7. Support Spacing for Schedule 80 Polypropylene Pipe: Maximum Span Nominal Pipe Diameter (at 100 degrees F) (inches) (feet)
1/2 3 3/4 3.5 1 3.75 1-1/4 4 1-1/2 4.25 2 4.5 3 5.5 4 6 6 7.25 8 8 10 8.75 12 9.5
8. Support Spacing for Fiberglass Reinforced Plastic (FRP) Pipe: Maximum Span Nominal Pipe Diameter (at 100 degrees F) (inches) (feet)
2 8.8 3 10 4 11 6 12.7 8 13.4 10 14 12 15.4 14 16.2 16 17.3 18 nd Greater 18
2.3 MANUFACTURED SUPPORTS
A. Stock Parts: Where not specifically indicated, designs which are generally accepted as exemplifying good engineering practice and use stock or production parts, shall be utilized wherever possible. Such parts shall be locally available, new, of best commercial quality, designed and rated for the intended purpose.
B. Manufacturers, or Equal
1. Basic Engineers Inc., Pittsburgh, PA. 2. Bergen-Paterson Pipesupport Corp., Woburn, MA. 3. Grinnell Corp. (Supply Sales Company), Cranston, RI 4. NPS Products, Inc., Westborough, MA. 5. Power Piping Company, Pittsburgh, PA.
BC&A PIPE SUPPORTS JVWCD PAGE 15006-6 CENTRAL PIPLINE PROJECT
2.4 COATING
C. Galvanizing: Unless otherwise indicated, fabricated pipe supports other than stainless steel or non-ferrous supports shall be blast-cleaned after fabrication and hot-dip galvanized in accordance with ASTM A 123 - Specifications for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products.
D. Other Coatings: Other than stainless steel or non-ferrous supports, all supports shall receive protective coatings in accordance with the requirements of Section 09900 – Coatings and Painting.
PART 3 – EXECUTION
3.1 INSTALLATION
A. General: Pipe supports, seismic restraints, hangers, brackets, anchors, guides, and inserts shall be fabricated and installed in accordance with the manufacturer's printed instructions and ASME B31.1 - Power Piping. Concrete inserts for pipe hangers and supports shall be coordinated with the form work.
B. Appearance: Pipe supports and hangers shall be positioned to produce an orderly, neat piping system. Hanger rods shall be vertical, without offsets. Hangers shall be adjusted to line up groups of pipes at the proper grade for drainage and venting, as close to ceilings or roofs as possible, without interference with other work.
3.2 FABRICATION
A. Quality Control: Pipe hangers, supports, and seismic restraints shall be fabricated and installed by experienced welders and fitters, using the best welding procedures available. Fabricated supports shall be neat in appearance without sharp corners, burrs, and edges.
END OF SECTION
BC&A PIPE SUPPORTS JVWCD PAGE 15006-7 CENTRAL PIPLINE PROJECT
SECTION 15007 NON-METALLIC PIPE SUPPORT SYSTEM
PART 1 - GENERAL
1.1 THE REQUIREMENT
A. The CONTRACTOR shall provide pipe supports, hangers, guides, and anchors, complete and in place, in accordance with the Contract Documents.
B. Where pipe support systems are not indicated on the Drawings, the CONTRACTOR shall design and provide the supports in accordance with this Section.
C. All pipe support systems shall be designed and constructed to withstand seismic loadings as outlined in Section 01612 - Seismic Design Criteria.
1.2 REFERENCES
A. American Society for Testing Materials (ASTM): 1. E 84 - Test Method for Surface Burning Characteristics of Building Materials.
1.3 SYSTEM DESCRIPTION
A. Design Responsibility: 1. The manufacturer of the non-metallic pipe support system shall be considered the designer of the support system. 2. Prepare design calculations utilizing the design criteria included in these Specifications. 3. Prepare detailed Shop Drawings illustrating the layout of the support system and identifying the components of the support system.
B. Design Requirements: 1. Include live, dead, and seismic loads associated with piping, valves, and appurtenances. Consider the content of the pipes in load calculations. 2. Maximum Allowable Deflection: 1/240 of span. 3. Allowable Column Loads: As recommended by manufacturer in published instruction for column's unsupported height and "K" value for calculating effective column length of not less than 1.0. 4. Future Loads: a. Support systems indicated on the Drawings may include spaces intended to accommodate future pipes. b. Assume such spaces are occupied by 6 inch diameter ductile iron pipes. Only the number of pipes that would physically fit into the space need be considered. c. Include the weight of the pipe contents in determining future loads. Assume pipe contents are water. 5. Seismic Design Criteria: Per subparagraph 1.1.C.
BC&A NON-METALLIC PIPE SUPPORT SYTSEM JVWCD PAGE 15007-1 CENTRAL PIPLINE PROJECT
6. Spacing of Supports: As required to comply with design requirements but not more than 5 feet.
1.4 SUBMITTALS
A. Submit in accordance with Section 01300 – Contractor Submittals.
B. Product data.
C. Shop Drawings: Include layout of support system including pipe loads, selected channel size, fittings, and appurtenances.
D. Structural design calculations.
E. Samples.
F. Manufacturer’s published instructions.
1.5 QUALITY ASSURANCE
A. Supply all materials from a single manufacturer with sole responsibility for the pipe support system.
B. The supplied system including pipe clamps, shall be interchangeable with industry standard 1-5/8 inch steel and fiberglass channel framing systems.
1.6 DELIVERY, STORAGE, AND HANDLING
A. Transportation, handling, storage, and installation shall be in accordance with the manufacturer’s printed instructions.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. One of the following or equal: 1. StrutTech, Redmond, Washington. 2. Unistrut, Wayne, Michigan.
2.2 MATERIALS
A. Fiberglass Resin: Corrosion resistant premium grade vinylester.
B. Injection Molded Components: Polyurethane thermoplastics.
C. Flame Spread of Fiberglass: 1. Vinylester Fiberglass (Series VF): Class 1, ASTM E 84. 2. Polyurethane: V-O UL 94V.
D. Physical Properties of Fiberglass:
BC&A NON-METALLIC PIPE SUPPORT SYTSEM JVWCD PAGE 15007-2 CENTRAL PIPLINE PROJECT
Longitudinal Transverse Tensile Strength 37,500 pounds per 10,000 pounds per square inch, (psi) square inch, (psi) Tensile Modules 3.0 X 106 psi 1.0 X 106 psi Flexural Strength 37,500 psi 14,000 psi Flexural Modules 2.0 X 106 psi 1.0 X 106 psi Compressive Strength 37,500 psi 20,000 psi Shear Strength 6,000 psi 5,500 psi Izod Impact 30 foot-pounds per 5 foot-pounds per square inch square inch
E. Surface Veil: Fiberglass channel shall have polyester surface veil over 100 percent of the surface to provide protection against degradation from ultraviolet light.
F. Touch-up Resin: 1. Manufacturers: One of the following or equal: a. Krylon, 7006-Satin Polyurethane Clear Finish.
2.3 COMPONENTS
A. Channel Framing: 1. All channel framing shall be supplied with integral notches 1 inch on center. 2. Locate notches on interior flange to prevent slippage of pipe clamps and fittings after installation.
B. Pipe Clamps: 1. Adjustable Type: Non-metallic and non-conductive. 2. Fixed Type: a. Pipe clamps for pipe less than 6 inches in diameter shall be non-metallic and non-conductive. b. Pipe clamps for pipe equal to and greater than 6 inches in diameter shall be fiberglass.
C. Channel Fittings: 1. Make fittings and post bases from glass-filled polyurethane or polyester.
D. Fasteners: 1. Make fasteners from one of the following materials: a. Glass-filled polyurethane. b. Vinylester fiberglass.
BC&A NON-METALLIC PIPE SUPPORT SYTSEM JVWCD PAGE 15007-3 CENTRAL PIPLINE PROJECT
PART 3 - EXECUTION
3.1 INSTALLATION
A. General: Pipe supports, hangers, brackets, anchors, guides, and inserts shall be fabricated and installed in accordance with the manufacturer's printed instructions and ASME B31.1 - Power Piping. Concrete inserts for pipe hangers and supports shall be coordinated with the formwork. Seal machined edges and holes with touch-up resin.
B. Appearance: Pipe supports and hangers shall be positioned to produce an orderly, neat piping system. Hanger rods shall be vertical, without offsets. Hangers shall be adjusted to line up groups of pipes at the proper grade for drainage and venting, as close to ceilings or roofs as possible, without interference with other WORK.
END OF SECTION
BC&A NON-METALLIC PIPE SUPPORT SYTSEM JVWCD PAGE 15007-4 CENTRAL PIPLINE PROJECT SECTION 15010 MILL PIPING – EXPOSED AND BURIED
PART 1 – GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall furnish and install all exposed and buried mill piping (pipe diameter 6 inches and less) as shown and in accordance with Contract Documents. This section applies to all mechanical Work and associated piping systems. Work related specifically to plumbing piping systems shall be performed in accordance with Section 15430 – Plumbing Piping and Fittings.
B. All work shall be in strict accordance with the International Plumbing Code, and codes of the State of Utah, City of Riverton, and any other authorities having jurisdiction. The Contractor shall have required certifications and be thoroughly familiar with the local codes. The Contractor shall obtain and pay for all necessary permits.
C. This section outlines requirements the following small (pipe diameter 6 inches and less) mechanical piping and associated accessories: 1. Small steel pipe 2. Solvent welded PVC pipe and Valves 3. CPVC pipe and Valves 4. PVDF pipe
D. The Contractor shall furnish hoses, hose racks and signage where indicated on the Drawings and as indicated herein.
1.2 REFERENCE STANDARDS
A. Commercial Standards
ANSI/ASME B16.3 Malleable Iron Threaded Fittings
ANSI/ASME B16.4 Gray Iron Threaded Fittings,
ASMEB16.5 Pipe Flanges and Flanged Fittings,
ANSI B16.11 Forged Steel Fittings, Socket-Welding and Threaded
ANSI B16.12 Cast-Iron Threaded Drainage Fittings
ANSI/ASME B16.15 Cast Bronze Threaded Fittings, Classes 125 and 250
ANSI B16.21 Nonmetallic Flat Gaskets for Pipe Flanges
ANSI B16.22 Wrought Copper and Copper Alloy Solder Joint Pressure Fittings
BC&A MILL PIPING – EXPOSED AND BURIED JVWCD PAGE 15010-1 CENTRAL PIPLINE PROJECT ASTM A 53 Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated Welded and Seamless
ASTM A 74 Specification for Cast Iron Soil Pipe and Fittings
ASTM A 105 Specification for Carbon Steel, Forgings for Piping Applications
ASTM A 106 Specification for Seamless Carbon Steel Pipe for High Temperature Service
ASTM A 312 Specification for Seamless and Welded Austenitic Stainless Steel Pipe
ASTM A 518 Specification for Corrosion-Resistant High-Silicon Iron Castings
ASTM B 43 Specification for Seamless Red Brass Pipe, Standard Sizes
ASTM B 62 Specification for Composition Bronze or Ounce Metal Castings
ASTM B 88 Specifications for Seamless Copper Water Tube
ASTM C 599 Specification for Conical Process Glass Pipe and Fittings.
ASTM D 1785 Specification for Poly (Vinyl Chloride) (PVC) Plastic Pipe, Schedules 40, 80, and 120
ASTM D 2996 Specification for Filament-Wound Reinforced Thermosetting Resin Pipe
ASTM D 3222 Specification for Unmodified Poly (Vinylidene Fluoride) (PVDF) Molding, Extrusion, and Coating Materials
ASTM D 4101 Specification for Propylene Plastic Injection and Extrusion Materials
ASTM F 441 Specification for Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe, Schedules 40 and 80
Chlorine Institute Pamphlet 6 Piping Systems for Dry Chlorine
BC&A MILL PIPING – EXPOSED AND BURIED JVWCD PAGE 15010-2 CENTRAL PIPLINE PROJECT 1.3 CONTRACTOR SUBMITTALS
A. For the materials and equipment items supplied under the provisions of this Section, submit copies of the manufacturer's product specifications and performance details according to the requirements of Section 01300 - Contractor Submittals.
B. Product information for all valves shall be submitted in accordance with Section 15200 – Valves, General.
PART 2 – PRODUCTS
2.1 SMALL STEEL PIPE (SYSTEMS 1, 2, 3 AND 6)
A. Unless otherwise indicated, galvanized steel pipe and black steel pipe in sizes 6 inches in diameter and smaller shall conform to the requirements of ASTM A 53 or ASTM A 106, as called out in the piping schedule and shall be Schedule 40 or 80 as indicated. Galvanized steel pipe shall not be cement mortar lined unless otherwise indicated. Fittings for galvanized steel pipe shall be of galvanized malleable iron, with NPT or grooved ends. Black pipe may have welded joints, with standard or extra strong welding fittings, or fittings indicated. Wall thickness of wrought-steel pipe shall comply with ASME B36.10M. 1. Malleable-Iron Threaded Fittings: ASME B16.3, Class 150, standard pattern, with threaded ends according to ASME B1.20.1. 2. Steel Threaded Fittings: ASME B16.11, forged steel with threaded ends according to ASME B1.20.1. 3. Steel Welding Fittings: ASME B16.9, wrought steel or ASME B16.11, forged steel. 4. Unions: ASME B16.39, Class 150, malleable iron with brass-to-iron seat, ground joint, and threaded ends according to ASME B1.20.1. Unions shall be as manufactured by Henry Valve Company; Vogt Valve Co.; or equal. 5. Cast-Iron Flanges and Flanged Fittings: ASME B16.1, Class 125. 6. Joint Compound and Tape: Suitable for natural gas. 7. Steel Flanges and Flanged Fittings: ASME B16.5. 8. Gasket Material: Thickness, material, and type suitable for natural gas.
2.3 COPPER TUBING (SYSTEM 24)
A. Hard Copper Tube and Fittings: ASTM B 88, Type L and ASTM B 88, Type M water tube, drawn temper. 1. Cast-Copper Solder-Joint Fittings: ASME B16.18, pressure fittings. 2. Wrought-Copper Solder-Joint Fittings: ASME B16.22, wrought-copper pressure fittings. Solder Filler Metals: ASTM B 32, 95-5 tin antimony. 3. Bronze Flanges: ASME B16.24, Class 150, with solder-joint ends. 4. Copper Unions: MSS SP-123, cast-copper-alloy, hexagonal-stock body, with ball-and-socket, metal-to-metal seating surfaces, and solder-joint or threaded ends.
BC&A MILL PIPING – EXPOSED AND BURIED JVWCD PAGE 15010-3 CENTRAL PIPLINE PROJECT 5. Copper Pressure-Seal-Joint Fittings: a. Manufacturers: Subject to compliance with requirements, provide products by one of the following: Elkhart Products Corporation; Industrial Division; NIBCO INC.; Viega; Plumbing and Heating Systems. b. NPS 2 and Smaller: Wrought-copper fitting with EPDM-rubber O-ring seal in each end. c. NPS 2-1/2 to NPS 4: Cast-bronze or wrought-copper fitting with EPDM- rubber O-ring seal in each end. 6. Copper Push-on-Joint Fittings: a. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1) NVent LLC. b. Description: Cast-copper fitting complying with ASME B16.18 or wrought- copper fitting complying with ASME B 16.22; with stainless-steel teeth and EPDM-rubber O-ring seal in each end instead of solder-joint ends.
B. Soft Copper Tube and Fittings: ASTM B 88, Type K and ASTM B 88, Type L water tube, annealed temper. 1. Copper Solder-Joint Fittings: ASME B16.22, wrought-copper pressure fittings. 2. Copper Pressure-Seal-Joint Fittings: a. Manufacturers: Subject to compliance with requirements, provide products by one of the following: Elkhart Products Corporation; Industrial Division; NIBCO INC.; Viega; Plumbing and Heating Systems. b. NPS 2 and Smaller: Wrought-copper fitting with EPDM-rubber O-ring seal in each end. c. NPS 3 and NPS 4: Cast-bronze or wrought-copper fitting with EPDM- rubber O-ring seal in each end.
2.4 CPVC (CHLORINATED POLYVINYL CHLORIDE) PRESSURE PIPE, SOLVENT- WELDED (SYSTEM 17)
A. CPVC system and components shall conform to the requirements of Section 15065 – CPVC Pressure Pipe.
B. Solvent Cements for Joining CPVC Piping and Tubing shall conform to ASTM F 493 and the requirements of Section 15065 – CPVC Pressure Pipe.
C. CPVC Ball Valves shall conform to Section 15204 – Ball Valves.
D. CPVC Ball-Check and Swing-Check Valves shall comply with Section 15203 – Check Valves.
2.12 HOSE BIBBS AND HYDRANTS
A. All hose bibbs and hydrants in exposed locations subject to freezing shall be the non- freeze type. Hose bibbs connected to a non-potable water supply shall be provided with plastic or stainless-steel warning signs "DO NOT DRINK," in clearly legible letters, and permanently attached at the hose bibb. Hose bibbs shall be provided with vacuum breakers as furnished by Crane Co., American Standard, or equal.
BC&A MILL PIPING – EXPOSED AND BURIED JVWCD PAGE 15010-4 CENTRAL PIPLINE PROJECT B. Manufacturers, or Equal:
Dwg. Callout Fixture Type Description HB-1 Non-freeze Post-type Exposed bronze hydrant, post-type, depth of bury to suit local conditions; minimum 4 feet. 1. Woodward Mfg. Co., Model Iowa Y1
HB-2 Non-freeze wall-type Heavy duty bronze hydrant with nickel-bronze face, hinged cover, recessed box, and key. Length to suit wall. 1. Josam Mfg. Co., Series 71000 2. Jay R. Smith Mfg. Co., Fig. 5510/5511 3. Zurn Industries, Inc., Fig. Z-1300
HB-3 Hose valves Heavy duty bronze hydrant, with composition disc, handwheel, cap and chain. Sizes 1 1/2-inch and 2 1/2 inch: 1. Fire-End and Croker Corp, Model 180 2. James Jones (Watts Regulator Co., Nos. J-383 and J-344, respectively
Size 1-inch, without cap and chain: 1. Apollo (Conbraco Industries, Inc.), Model 70-805 2. Fire-End and Croker Corp, Model 180
Size 3/4-inch, without cap and chain: 1. Apollo (Conbraco Industries, Inc.) Model 70-804, or 78-104 2. Chicago Faucet No.7T 3. Ford Meter Box Co., Model B8H-233HB2 4. Woodford Manufacturing Co., Model Y24 or 24P
HB-4 Wall box type Recessed, with nickel-bronze box, hinged cover, and key. 1. Josam Mfg. Co., Series 71020 2. Jay R. Smith Mfg. Co., Series 5710 3. Zurn Industries, Inc., Fig. Z-1345
2.13 SHOCK ABSORBERS
A. Install shock absorbers in accordance with Section 15430 – Plumbing Piping and Fittings.
BC&A MILL PIPING – EXPOSED AND BURIED JVWCD PAGE 15010-5 CENTRAL PIPLINE PROJECT 2.14 ACCESS DOORS AND COVERS
A. Install access doors and covers in accordance with Section 15430 – Plumbing Piping and Fittings.
2.15 WALL-MOUNTED HOSE RACKS
A. The Contractor shall provide wall-mounted hose racks at locations indicated. Racks shall be all welded steel construction, of minimum 8-gage sheet steel, hot-dip galvanized after fabrication, and shall have a capacity to hold 100 feet of 3/4-inch or 1-1/2-inch hose. Where racks are located in the open, they shall be supported from two 2- by 2- by 1/4-inch galvanized steel angle posts set in a concrete base or as indicated.
2.16 HOSES AND NOZZLES
A. The Contractor shall furnish the following lengths of hose: 1. 1 - 50 ft lengths of 3/4-inch diameter hose 2. 1 - 75 ft lengths of 1-inch diameter hose
B. Each length of hose shall be provided with male and female connectors and nozzle. Hoses shall be seamless extruded rubber with dacron cotton exterior designed for a working pressure of at least 200 psi.
C. Nozzles shall be capable of complete shut-off and shall produce a solid straight stream and up to a 90-degree conical fog. Nozzle material shall be polished brass. Nozzles shall have rubber bumpers.
D. Nozzle Manufacturers, or Equal: 1. W.D. Allen Mfg. Co., Illinois 2. Fire-End and Crocker Corp., New York 3. Halprin Supply Co., Illinois 4. Western Fire Equipment Co., California
2.20 GASKETS AND BOLTS
A. Except as otherwise indicated, gaskets for flanged joints shall be in accordance with the requirements of Section 15000 - Piping, General.
B. Except as otherwise indicated, bolts shall conform to the requirements of Section 05500 – Miscellaneous Metalwork.
2.21 INSULATING CONNECTIONS
A. Insulating bushings, unions, couplings or flanges, as appropriate, shall be used for joining pipes of dissimilar metals, and for piping systems where corrosion control and cathodic protection are involved, in accordance with the requirements of Section 15430 –Plumbing Piping and Fittings.
BC&A MILL PIPING – EXPOSED AND BURIED JVWCD PAGE 15010-6 CENTRAL PIPLINE PROJECT 2.22 PIPE INSULATION
A. Hot and cold liquid piping shall be installed in accordance with Section 15430 – Plumbing Piping and Fittings.
2.23 PIPE SUPPORTS
A. Pipe Supports, hangers, anchors, seismic restraints, and guides shall be in accordance with the requirements of Section 15006 - Pipe Supports.
PART 3 – EXECUTION
3.1 INSTALLATION
A. Small Steel Pipe: Buried galvanized or black steel pipe shall be coated as specified in Section 09900 – Coatings and Painting or provided with an extruded high density polyethylene coating with minimum thickness of 35 mils.
B. Plastic Pipe: PVC, CPVC, and FRP pipe joints shall be solvent-welded in accordance with the manufacturer's instructions. Expansion joints or pipe bends shall be provided to absorb pipe expansion over a temperature range of 100 degrees F, unless otherwise indicated. Care shall be taken to provide sufficient supports, anchors, and guides, to avoid stress on the piping. Obtain the services of the pipe manufacturer, to instruct the pipe fitters in the correct way of making solvent welded and threaded joints. Only clean, fresh primer and solvent shall be used at all times at the recommended temperatures.
C. Drain Traps: Drain traps shall be installed at low points in air and gas lines or elsewhere where indicated. Liquid outlets shall be piped to the nearest floor drain or open sump.
D. Couplings: Pipe couplings shall be installed in strict accordance with the manufacturer's printed recommendations, using the correct style coupling and gasket for any given application.
E. Gaskets for Flanged Joints: Gaskets shall be in accordance with the requirements of Section 15000 - Piping, General.
F. Insulating Connections: All insulating connections shall be installed in accordance with manufacturer's printed instructions. Care shall be exercised to prevent damage to insulating fittings, while making up the joints.
3.2 CONTINUITY BONDS
A. Where required by the Contract Documents, all metallic pipe joints, except field-welded joints and insulating joints, shall be continuity bonded in accordance with the requirements of Section 15000 - Piping, General.
- END OF SECTION-
BC&A MILL PIPING – EXPOSED AND BURIED JVWCD PAGE 15010-7 CENTRAL PIPLINE PROJECT
SECTION 15052 COMMON WORK RESULTS FOR PLUMBING AND HVAC
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section includes the following: 1. Record Documents, Maintenance Manuals, and General Provisions for mechanical work. 2. Piping materials and installation instructions common to most piping systems. 3. Equipment installation requirements common to equipment sections.
1.3 QUALITY ASSURANCE
A. Electrical Characteristics for Mechanical Equipment: Equipment of higher electrical characteristics may be furnished provided such proposed equipment is approved in writing by the engineer and connecting electrical services, circuit breakers, and conduit sizes are appropriately modified without added cost to Project. If minimum energy ratings or efficiencies are specified, equipment shall comply with requirements.
1.4 COORDINATION
A. Arrange for pipe spaces, chases, slots, and openings in building structure during progress of construction, to allow for mechanical installations.
B. Coordinate requirements for access panels and doors for mechanical items requiring access that are concealed behind finished surfaces.
1.5 FEES AND PERMITS
A. Contractor shall apply and pay for all permits, inspections, reviews, etc. required by the authorities having jurisdiction. 1. This shall include the cost of extending the natural gas service from the utility company main line to the building meter, setting the meter and regulator and all related utility company costs. 2. The Contractor shall include in his/her Bid all system development or similarly named fee imposed by the serving utility company or governing entity (City, County, etc.).
BC&A COMMON WORK RESULTS JVWCD FOR PLUMBING AND HVAC CENTRAL PIPELINE PROJECT PAGE 15052-1 1.6 RECORD DOCUMENTS
A. Prepare Record Documents in accordance with the requirements in Division 1 Section "PROJECT CLOSEOUT." In addition to the requirements specified in Division 1, indicate the following installed conditions: 1. Ductwork mains and branches, size and location, for both exterior and interior; locations of dampers and other control devices; filters, boxes, and terminal units requiring periodic maintenance or repair. 2. Mains and branches of piping systems, with valves and control devices located and numbered, concealed unions located, and with items requiring maintenance located (ie. traps, strainers, tanks, etc.). Refer to Section 15076 "Identification for HVAC Piping and Equipment". Indicate actual inverts and horizontal locations of underground piping. 3. Equipment locations (exposed and concealed) dimensioned from prominent building lines. 4. Approved substitutions, Contract Modifications, and actual equipment and materials installed. Revise equipment schedules. 5. Contract Modifications, actual equipment and materials installed.
1.7 MAINTENANCE MANUALS
A. Prepare maintenance manuals in accordance with Division 1 Section "PROJECT CLOSEOUT." In addition to the requirements specified in Division 1. Assemble O & M Manuals as follows: 1. Compile three copies of Operating and Maintenance Manuals for the mechanical systems and equipment. The manuals shall be provided to the Architect for approval complete and at one time, prior to requesting final payment. Partial or separate data will be returned for completion. 2. Manuals shall be assembled in three-ring binders. Binders shall be 3 inches thick or less and more than one binder shall be used for each set of data if required to prevent overfilling of one binder. Binders shall have plastic coating with correct name of the Project permanently attached to the spine. Binders shall be Sparco, #68031. All information shall be arranged in sections and each section shall have a blank buff colored, heavy paper divider with a protruding tab clearly labeled. Sections shall be arranged in the same order that the equipment is listed in the Specification and each Specification Section shall have a separate tab. Shop Drawings which are larger than 8-1/2 inches x 11 inchesshall be individually folded so they are 8-1/2 inches x 11 inches or less and inserted behind the appropriate tab. 3. Tabs shall be labeled and arranged as follows: a. Index: Furnish under the first tab an index of sections listing name of Section and Specification numbers. b. Equipment Manufacturers: Furnish under the second tab a complete typed list of equipment suppliers and manufacturers representative including type of equipment, name, address and phone number. The company listed here should be the one which could furnish replacement parts and offer technical information about the equipment. c. Valve Directory: Furnish under this tab a typed copy of the valve chart required.
BC&A COMMON WORK RESULTS JVWCD FOR PLUMBING AND HVAC CENTRAL PIPELINE PROJECT PAGE 15052-2 d. Product Literature: Each tab, starting with the fourth shall contain the name of a Specification Section. Behind each tab shall be the previously submitted and approved Shop Drawing, factory published operation and maintenance instructions and parts lists. 4. Upon completion and approval of the booklets, one copy shall be given to the Architect, and two to the Owner. Using the booklet, the Mechanical Contractor shall explain in detail and instruct the Owner's operating personnel in the correct operation and maintenance of the equipment.
1.8 GENERAL PROVISIONS FOR MECHANICAL WORK
A. Interferences: Project design took into account potential interferences between trades (e.g. mechanical ductwork with piping or with electrical light fixtures), however, not every interference has been eliminated. It shall be the responsibility of the Bidder and potential Contractor to field verify all mechanical piping and duct routing, making allowances for existing beams, pipes, ducts, hangers, and other obstructions. Provide HVAC duct offsets and transitions as required maintaining duct aspect ratios within 10 percent of design. The cost associated with interferences shall be included in the Base Bid.
B. Examination of Project Drawings: 1. The Drawings (Plans, elevations, flow schematics, etc.) for the mechanical work are intended to convey Scope of Work and to indicate the general arrangements and locations of end-use equipment, systems, etc., and the approximate sizes thereof. 2. The Contractor shall determine the exact location and mounting heights of equipment, rough-ins, and the exact routing and positioning of piping/ductwork equipment so as to best fit the layout of the job. Scaling of the Drawings will not be sufficient for determining these locations. Where job conditions require reasonable changes in indicated arrangements and locations, such changes shall be made, by the Contractor, at no additional cost to the Client. 3. Because of the scale of the Drawings, certain basic items/materials and quantities thereof, (e.g. fittings, connectors, flanges, unions, pipe wells, couplings, hangers, sleeves, clamps, screws, hooks, inserts, pipe/duct mounted - meters, gauges, sensors, etc.) may not be shown, but where such items are required by other sections of the Specifications or where they are required for proper installation of the Work, such items shall be furnished and installed and the cost thereof, reflected in the Base Bid. 4. The determination of quantities of HVAC and plumbing end-use systems and equipment required shall be made by the Contractor from the Drawings. Interferences and quantities and locations of basic items/materials may not be indicated on the Drawings and will require field verification and determination by the Contractor. 5. The Contractor shall coordinate the location and method of support of the piping/duct systems with that of all installations under other Divisions and Sections of the Specifications.
BC&A COMMON WORK RESULTS JVWCD FOR PLUMBING AND HVAC CENTRAL PIPELINE PROJECT PAGE 15052-3 PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. In other Part 2 articles where subparagraph titles below introduce lists, the following requirements apply for product selection: 1. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the manufacturers specified. 2. Manufacturers: Subject to compliance with requirements, provide products by the manufacturers specified.
2.2 PIPE, TUBE, AND FITTINGS
A. Refer to individual Division 15 piping Sections for pipe, tube, and fitting materials and joining methods.
2.3 JOINING MATERIALS
A. Refer to individual Division 15 piping Sections for special joining materials not listed below.
B. Solvent Cements for Joining Plastic Piping: 1. PVC Piping: ASTM D 2564. Include primer according to ASTM F 656.
PART 3 - EXECUTION
3.1 PIPING SYSTEMS - COMMON REQUIREMENTS
A. Drawing Plans, schematics, and diagrams indicate general location and arrangement of piping systems. Indicated locations and arrangements were used to size pipe and calculate friction loss, expansion, pump sizing, and other design considerations. Install piping as indicated unless deviations to layout are approved on Coordination Drawings.
B. Install piping in concealed locations, unless otherwise indicated and except in equipment rooms and service areas.
C. Install piping indicated to be exposed and piping in equipment rooms and service areas at right angles or parallel to building walls. Diagonal runs are prohibited unless specifically indicated otherwise.
D. Install piping at indicated slopes.
E. Install piping free of sags and bends.
F. Install fittings for changes in direction and branch connections.
G. Select system components with pressure rating equal to or greater than system operating pressure.
BC&A COMMON WORK RESULTS JVWCD FOR PLUMBING AND HVAC CENTRAL PIPELINE PROJECT PAGE 15052-4 3.2 PIPING JOINT CONSTRUCTION
A. Join pipe and fittings according to the following requirements.
B. Ream ends of pipes and tubes and remove burrs.
C. Remove scale, slag, dirt, and debris from inside and outside of pipe and fittings before assembly.
D. Plastic Piping Solvent-Cement Joints: Clean and dry joining surfaces. Join pipe and fittings according to the following: 1. Comply with ASTM F 402 for safe-handling practice of cleaners, primers, and solvent cements. 2. PVC Nonpressure Piping: Join according to ASTM D 2855.
3.3 EQUIPMENT INSTALLATION - COMMON REQUIREMENTS
A. Install equipment to allow maximum possible headroom unless specific mounting heights are not indicated.
B. Install equipment level and plumb, parallel and perpendicular to other building systems and components in exposed interior spaces, unless otherwise indicated.
C. Install mechanical equipment to facilitate service, maintenance, and repair or replacement of components. Connect equipment for ease of disconnecting, with minimum interference to other installations. Extend grease fittings to accessible locations.
D. Install equipment to allow right of way for piping installed at required slope.
END OF SECTION
BC&A COMMON WORK RESULTS JVWCD FOR PLUMBING AND HVAC CENTRAL PIPELINE PROJECT PAGE 15052-5
SECTION 15065 CPVC PRESSURE PIPE
PART 1 – GENERAL
1.1 THE REQUIREMENT
A. The CONTRACTOR shall provide Chlorinated Polyvinyl Chloride (CPVC) pressure pipe, complete and in place, in accordance with the Contract Documents.
B. The requirements of Section 15000 - Piping, General, apply to the WORK of this Section.
PART 2 – PRODUCTS
2.1 PIPE MATERIAL
A. CPVC pipe shall be in accordance with ASTM F 441 - Chlorinated Poly (Vinyl Chloride) (CPVC), Plastic Pipe, Schedules 40, and 80, from all new compounds, meeting the requirements of Class 23447 per ASTM D 1784 - Rigid Poly (Vinyl Chloride) (PVC) Compounds and Chlorinated Poly (Vinyl Chloride) (PVC) Compounds. CPVC pipes shall be Schedule 80 pipe, unless otherwise indicated. CPVC material shall be listed as compliant with NSF Standard 61.
2.2 PIPE JOINTS
A. Pipe joints shall be solvent-welded with solvent cement in accordance with ASTM F 493 - Solvent Cements for Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe and Fittings, and with primer in accordance with ASTM F 656 - Primers for Use in Solvent Cement Joints of Poly (Vinyl Chloride) (PVC) Plastic Pipe and Fittings. Screwed joints which are necessary to match up to threaded valves or fittings shall be made up with appropriate thread sealant, either paste or tape. Flanged joints shall be made with solvent-welded CPVC flanges, drilled to ANSI/ASME B 16.5 - Pipe Flanges and Flanged Fittings, Class 150, unless otherwise indicated. For CPVC or PVC pipe used in chemical service, solvent welded joints shall be done using IPS Corp Type 724 cement or another cement certified by the manufacturer for chemical service.
2.3 FITTINGS
A. Solvent-Welded Fittings: Solvent-welded fittings shall be Schedule 80 CPVC fittings in accordance with ASTM F 439 - Socket-Type Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe Fittings, Schedule 80.
B. Threaded Fittings: Threaded fittings shall be Schedule 80 CPVC fittings in accordance with ASTM F 437 - Threaded Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe Fittings, Schedule 80.
C. Flanged Fittings: Flanged fittings shall be fabricated Schedule 80 CPVC fittings with 150 lb. flanges to ANSI/ASME B 16.5. Gaskets shall be ANSI 150 lb. full face, 1/8-inch thick
BC&A CPVC PRESSURE PIPE JVWCD PAGE 15065-1 CENTRAL PIPLINE PROJECT Neoprene for water or wastewater service. Gasket material for chemicals shall be suitable for use with the chemical service.
2.4 COATINGS
A. Outside of CPVC piping and fittings shall be coated to conform to the requirements of Section 09900 – Coatings and Painting.
PART 3 – EXECUTION
3.1 INSTALLATION
A. General: CPVC pipes shall be installed in a neat and workmanlike manner, properly aligned, and cut from measurements taken at the Site to avoid interferences with structural members, architectural features, openings, and equipment. Exposed pipes shall afford maximum headroom and access to equipment, and where necessary piping shall be installed with sufficient slopes for venting or drainage of liquids and condensate to low points. The entire installation shall be acceptable to the ENGINEER. It is recommended that the CONTRACTOR obtain the assistance of the pipe manufacturer's field representative to instruct the pipe fitters in the correct installation and support of all CPVC piping.
B. Supports and Anchors: Piping shall be firmly supported with fabricated or commercial hangers or supports in accordance with Section 15006 - Pipe Supports. Where necessary to avoid stress on equipment or structural members, the pipes shall be anchored or harnessed. Expansion joints and guides shall compensate for pipe expansion due to temperature differences. Where piping support is metallic, Contractor shall provide and install unicusion or other acceptable piping protective shield to encompass the entire portion of pipe in contact with the support material.
C. Valves and Unions: Unless otherwise indicated, connections to fixtures, groups of fixtures, and equipment shall be provided with a shutoff valve and union, unless the valve has flanged ends. Unions shall be provided at threaded valves, equipment, and other devices requiring occasional removal or disconnection. Valves and flanges attached to CPVC pipe shall be provided with adequate supports.
3.2 PIPE PREPARATION
A. Prior to installation, each pipe length shall be carefully inspected, flushed clean of any debris or dust, and straightened, if not true. Ends of threaded pipes shall be reamed and filed smooth. Pipe fittings shall be equally cleaned before assembly.
3.3 PIPE JOINTS
A. Threaded Joints: Pipe threads shall conform to ASTM F 1498-Taper Pipe Threads 600 for Thermoplastic Pipe and Fittings, and shall be full and cleanly cut with sharp dies or molded. Joints shall be mode with Teflon tape or thread sealant.
B. Solvent-Welded Joints: Solvent-welded joints shall be made with fresh primer and solvent cement on clean, dry pipe ends. The primer and cement cans shall be kept
BC&A CPVC PRESSURE PIPE JVWCD PAGE 15065-2 CENTRAL PIPLINE PROJECT closed at all times and the joints shall be made up at the recommended ambient temperatures, to the pipe or cement manufacturer's written recommendations. Pipe ends shall be inserted to the full depth of the socket.
C. Flanged Fittings: Flanged joints shall be made with gaskets and Type 316 stainless steel bolts and nuts. Care shall be taken not to over-torque the bolts, in accordance with the manufacturer's written recommendations.
3.4 INSPECTION AND FIELD TESTING
A. Inspection: Finished installations shall be carefully inspected for proper joints and sufficient supports, anchoring, interferences, and damage to pipe, fittings, and coating. Any damages shall be repaired by the Contractor to the satisfaction of the ENGINEER.
B. Field Testing: The CONTRACTOR shall allow adequate time for the solvent cement joints to cure. Curing time shall be per the solvent cement manufacturer's recommendation. Prior to enclosure or burying, piping systems shall be pressure tested as required in the Piping Schedule for a period of not less than one hour, without exceeding the tolerances listed in the Piping Schedule. CAUTION – DO NOT use air or gas for testing CPVC pipe. Where no pressures are indicated, the pipes shall be subject to 1-1/2 times the maximum working pressure. The CONTRACTOR shall furnish all test equipment, labor, materials, and devices.
C. Leakage shall be determined by loss of pressure. Fixtures, devices, or other accessories which are to be connected to the lines and which would be damaged if subjected to the test pressure shall be disconnected and ends of the branch lines plugged or capped as required during the testing procedures.
D. Leaks shall be repaired by the Contractor to the satisfaction of the ENGINEER and the system shall be re-tested as required until no leaks are found.
- END OF SECTION -
BC&A CPVC PRESSURE PIPE JVWCD PAGE 15065-3 CENTRAL PIPLINE PROJECT
SECTION 15071 SEISMIC CONTROLS FOR PLUMBING AND HVAC
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section.
1.2 SUMMARY
A This Section includes the following: 1. Restrained Isolators 2. Restraining braces and cables
B It is the intent of this section to have the seismic bracing requirements designed by the approved seismic equipment manufacturer and installed by the mechanical contractor. The seismic manufacturer shall be responsible for the structural design of attachment hardware as required to attach snubbers to both the equipment and supporting structure. The manufacturer shall submit seismic shop drawings showing type and location of re- straint devices as required to meet the code and performance requirements specified herein. The work under this section shall include all materials and labor necessary for complete execution of installation of seismic restraint assemblies as required per IBC code requirements.
C The requirements of this seismic restraint section are in addition to other requirements as specified for support and attachment of equipment and mechanical services.
1.3 DEFINITIONS
A IBC: International Building Code.
1.4 PERFORMANCE REQUIREMENT
A Seismic-Restraint Loading: 1. Assigned Seismic Use Group or Building Category as Defined in the IBC. a. Component Importance Factor: (1.0) for all ductwork, equipment and pip- ing except (1.5) for Natural gas piping. b. Component Response Modification Factor: As required by IBC 2006 and ASCE 7-05 for specific component. c. Component Amplification Factor: As required by IBC 2006 and ASCE 7- 05 for specific component 2. Refer to Structural Design for Spectral Response Acceleration
1.5 SUBMITTALS
A Product Data: For the following: 1. Illustrate and indicate style, material, strength, fastening provision, and finish for each type and size of seismic-restraint component used.
CTA ARCHITECTS ENGINEERS SEISMIC CONTROLS FOR JVWCD PLUMBING AND HVAC CENTRAL PIPELINE PROJECT PAGE 15071 - 1
a. Tabulate types and sizes of seismic restraints, complete with report num- bers and rated strength in tension and shear. b. Annotate to indicate application of each product submitted and compliance with requirements. 2. Interlocking Snubbers: Include ratings for horizontal, vertical, and combined loads.
B Delegated-Design Submittal: For seismic-restraint details indicated to comply with perfor- mance requirements and design criteria, including analysis data signed and sealed by the qualified professional engineer responsible for their preparation. 1. Design Calculations: Calculate requirements for selecting seismic restraints. Cer- tification documents to be signed and sealed by a qualified Professional Engineer with at least 5 years experience in the design of seismic restraints. 2. Seismic Restraint Details: Detail submittal drawings of seismic restraints and snubbers. Show anchorage details and indicate quantity, diameter, and depth of penetration anchors. 3. Seismic Shop Drawings: Floor Plans indicating seismic bracing locations and spacing for HVAC piping, ductwork and equipment.
1.6 QUALITY ASSURANCE
A Comply with seismic-restraint requirements in the IBC unless requirements in this Section are more stringent.
B Welding: Qualify procedures and personnel according to AWS D1.1/D1.1M, "Structural Welding Code - Steel."
C Seismic restraint products shall be of the same manufacturer.
D Seismic-restraint devices shall have horizontal and vertical load testing and analysis and shall bear anchorage preapproval OPA number from OSHPD, preapproval by ICC-ES, or preapproval by another agency acceptable to authorities having jurisdiction, showing max- imum seismic-restraint ratings. Ratings based on independent testing are preferred to ratings based on calculations. If preapproved ratings are not available, submittals based on independent testing are preferred. Calculations (including combining shear and tensile loads) to support seismic-restraint designs must be signed and sealed by a qualified pro- fessional engineer.
E All piping and ductwork is to be retrained to meet code requirements. The seismic restraint manufacturer will provide documentation on maximum restraint spacing for various cable sizes and anchors. In addition, the seismic restraint manufacturer will provide support documentation containing adequate information to allow the installation contractor to make reasonable field modifications to suit special case conditions.
F Seismic Restraint Designers/Manufacturers: Subject to compliance with requirements provide seismic design services and products by one of the following: 1. Amber/Booth Co. Inc. 2. Kinetics Noise Control. 3. Mason Industries.
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PART 2 - PRODUCTS
2.1 RESTRAINED ISOLATORS
A Restrained Mounts: All-directional mountings with seismic restraint. 1. Materials: Ductile-iron or welded steel housing containing two separate and op- posing, oil-resistant rubber or neoprene elements that prevent central threaded element and attachment hardware from contacting the housing during normal op- eration. 2. Neoprene: Shock-absorbing materials compounded according to the standard for bridge-bearing neoprene as defined by AASHTO.
B Restrained Spring Isolators: Freestanding, steel, open-spring isolators with seismic or limit-stop restraint. 1. Housing: Steel with resilient vertical-limit stops to prevent spring extension due to weight being removed; factory-drilled baseplate bonded to 1/4-inch- thick, neo- prene or rubber isolator pad attached to baseplate underside; and adjustable equipment mounting and leveling bolt that acts as blocking during installation. 2. Restraint: Seismic or limit stop as required for equipment and authorities having jurisdiction. 3. Outside Spring Diameter: Not less than 80 percent of the compressed height of the spring at rated load. 4. Minimum Additional Travel: 50 percent of the required deflection at rated load. 5. Lateral Stiffness: More than 80 percent of rated vertical stiffness. 6. Overload Capacity: Support 200 percent of rated load, fully compressed, without deformation or failure.
2.2 SEISMIC-RESTRAINT DEVICES
A General Requirements for Restraint Components: Rated strengths, features, and appli- cations shall be as defined in reports by an agency acceptable to authorities having juris- diction. 1. Structural Safety Factor: Allowable strength in tension, shear, and pullout force of components shall be at least four times the maximum seismic forces to which they will be subjected.
B Snubbers: Factory fabricated using welded structural-steel shapes and plates, anchor bolts, and replaceable resilient isolation washers and bushings. 1. Anchor bolts for attaching to concrete shall be seismic-rated, drill-in, and stud- wedge or female-wedge type. 2. Resilient Isolation Washers and Bushings: Oil- and water-resistant neoprene. 3. Maximum 1/4-inch air gap, and minimum 1/4-inch- thick resilient cushion.
C Channel Support System: MFMA-3, shop- or field-fabricated support assembly made of slotted steel channels with accessories for attachment to braced component at one end and to building structure at the other end and other matching components and with corro- sion-resistant coating; and rated in tension, compression, and torsion forces.
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D Restraint Cables: ASTM A 603 galvanized steel cables pre-stretched with end connections made of steel assemblies with thimbles, brackets, swivel, and bolts designed for restrain- ing cable service; and with a minimum of two clamping bolts for cable engagement.
E Hanger Rod Stiffener: Steel tube or steel slotted-support-system sleeve with internally bolted connections or reinforcing steel angle clamped to hanger rod.
F Bushings for Floor-Mounted Equipment Anchor Bolts: Neoprene bushings designed for rigid equipment mountings, and matched to type and size of anchor bolts and studs.
G Bushing Assemblies for Wall-Mounted Equipment Anchorage: Assemblies of neoprene elements and steel sleeves designed for rigid equipment mountings, and matched to type and size of attachment devices used.
H Resilient Isolation Washers and Bushings: One-piece, molded, oil- and water-resistant neoprene, with a flat washer face.
I Mechanical Anchor Bolts: Drilled-in and stud-wedge or female-wedge type in zinc-coated steel for interior applications and stainless steel for exterior applications. Select anchor bolts with strength required for anchor and as tested according to ASTM E 488. Minimum length of eight times diameter.
J Adhesive Anchor Bolts: Drilled-in and capsule anchor system containing polyvinyl or ure- thane methacrylate-based resin and accelerator, or injected polymer or hybrid mortar ad- hesive. Provide anchor bolts and hardware with zinc-coated steel for interior applications and stainless steel for exterior applications. Select anchor bolts with strength required for anchor and as tested according to ASTM E 488.
PART 3 - EXECUTION
3.1 EXAMINATION
A Examine areas and equipment to receive seismic control devices for compliance with re- quirements for installation tolerances and other conditions affecting performance.
B Examine roughing-in of reinforcement and cast-in-place anchors to verify actual locations before installation.
C Proceed with installation only after unsatisfactory conditions have been corrected.
3.2 APPLICATIONS
A Multiple Pipe Supports: Secure pipes to trapeze member with clamps approved for appli- cation by an agency acceptable to authorities having jurisdiction.
B Hanger Rod Stiffeners: Install hanger rod stiffeners where indicated or scheduled on shop drawings to receive them and where required to prevent buckling of hanger rods due to seismic forces.
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C Strength of Support and Seismic-Restraint Assemblies: Where not indicated, select sizes of components so strength will be adequate to carry present and future static and seismic loads within specified loading limits.
3.3 SEISMIC-RESTRAINT DEVICE INSTALLATION
A Installation of all seismic restraint materials shall be installed according to the manufac- turer’s installation instructions and project shop drawings.
B Equipment Restraints: 1. Install seismic snubbers on HVAC equipment mounted on vibration isolators. Lo- cate snubbers as close as possible to vibration isolators and bolt to equipment base and supporting structure. Snubbers are not needed if restrained isolators are used. 2. Install resilient bolt isolation washers on equipment anchor bolts where clearance between anchor and adjacent surface exceeds 0.125 inch. 3. Install seismic-restraint devices using methods approved by an agency acceptable to authorities having jurisdiction providing required submittals for component.
C Piping Restraints: 1. Comply with requirements in MSS SP-127. 2. Space lateral supports and longitudinal supports as required for the site spectral response. 3. Brace a change of direction longer than 12 feet.
D Install cables so they do not bend across edges of adjacent equipment or building struc- ture.
E Install seismic-restraint devices using methods approved by an agency acceptable to au- thorities having jurisdiction providing required submittals for component.
F Install bushing assemblies for anchor bolts for floor-mounted equipment, arranged to pro- vide resilient media between anchor bolt and mounting hole in concrete base.
G Install bushing assemblies for mounting bolts for wall-mounted equipment, arranged to provide resilient media where equipment or equipment-mounting channels are attached to wall.
H Attachment to Structure: If specific attachment is not indicated, anchor bracing to structure at flanges of beams, at upper truss chords of bar joists, or at concrete members.
I Drilled-in Anchors: 1. Identify position of reinforcing steel and other embedded items prior to drilling holes for anchors. Do not damage existing reinforcing or embedded items during coring or drilling. Notify the structural engineer if reinforcing steel or other embedded items are encountered during drilling. Locate and avoid prestressed tendons, elec- trical and telecommunications conduit, and gas lines. 2. Do not drill holes in concrete or masonry until concrete, mortar, or grout has achieved full design strength.
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3. Wedge Anchors: Protect threads from damage during anchor installation. Heavy- duty sleeve anchors shall be installed with sleeve fully engaged in the structural element to which anchor is to be fastened. 4. Adhesive Anchors: Clean holes to remove loose material and drilling dust prior to installation of adhesive. Place adhesive in holes proceeding from the bottom of the hole and progressing toward the surface in such a manner as to avoid intro- duction of air pockets in the adhesive. 5. Set anchors to manufacturer's recommended torque, using a torque wrench. 6. Install zinc-coated steel anchors for interior and stainless-steel anchors for exterior applications.
3.4 ACCOMMODATION OF DIFFERENTIAL SEISMIC MOTION
A Install flexible connections in piping where they cross seismic joints, where adjacent sec- tions or branches are supported by different structural elements, and where the connec- tions terminate with connection to equipment that is anchored to a different structural ele- ment from the one supporting the connections as they approach equipment.
END OF SECTION
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SECTION 15075 METERS, GENERAL
PART 1 – GENERAL
1.1 THE REQUIREMENT
A. General: The CONTRACTOR shall furnish and install all meters and flow measurement devices with associated instrumentation and controls as shown and specified herein, complete and operable, in accordance with the requirements of the Contract Documents.
1.2 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS
A. Commercial Standards:
ANSI B16.1 Cast Iron Pipe Flanges and Flanged Fittings, Class 25, 125, 250, and 800
ANSI/AWWA C207 Steel Pipe Flanges for Waterworks Service – Sizes 4 In Through 144 In.
ANSI/AWWA C701 Cold-Water Meters – Turbine Type for Customer Service
ANSI/AWWA C702 Cold-Water Meters – Compound Type
AWWA A C704 Cold-Water Meters – Propeller Type for Main Line Applications
ASME REPORT Fluid Meters, Sixth Edition, 1971
ISA – S 5.1 Instrumentation Symbols and Identification
1.3 CONTRACTOR SUBMITTALS
A. Shop Drawings: The SUPPLIER shall submit complete Shop Drawings of all meters for review, in accordance with Section 01300 – Contractor Submittals. Each meter shall be identified with its equipment number, as shown or specified in the Contract Documents.
B. Manufacturer’s Data: With the Shop Drawings, furnish certified curves indicating flow versus differential pressure and any other information called for in the individual meter Specifications.
C. Technical Manuals: Furnish to the ENGINEER five (5) identical copies of complete operation and maintenance instructions of all the metering systems, including instrumentation and controls, manufacturer’s written guarantees and warranties, etc., as specified in Section 01300 – Contractor Submittals.
BC&A JVWCD METERS, GENERAL CENTRAL PIPELINE PROJECT PAGE 15075-1 D. Spare Parts: The CONTRACTOR shall provide a list of the Manufacturer’s recommended spare parts and, after the ENGINEER’S approval, shall furnish all spare parts suitably packaged and labeled for each meter device.
E. Special Tools: A list of special tools required shall be submitted to the ENGINEER for approval. After approval, the CONTRACTOR shall supply these tools suitably wrapped and identified for application.
1.4 QUALITY ASSURANCE
A. Accuracy Requirements: Unless otherwise specified herein, the flow meters shall be guaranteed to register flow to an accuracy of 0.5 percent of actual flow throughout the range specified.
PART 2 – PRODUCTS
2.1 ELECTROMAGNETIC FLOW METER
A. General: Magnetic flowmeter systems shall be of the low frequency electromagnetic induction type and produce a DC pulsed signal directly proportional to and linear with the liquid flow rate. Each magnetic flow metering system shall include a flow sensor, signal cable, transmitter, and grounding rings.
B. Flow Sensor: The flow sensor shall have the following attributes:
1. Materials
Body Carbon Steel Meter Coating Two component Epoxy Liner hard elastomer (hard rubber) Electrodes 316 Ti Stainless Steel Connections ANSI Class 150 Flanged
2. Utilize a minimum of two self-cleaning electrodes. 3. Rated for NEMA 6 submergence conditions. 4. Shall include two grounding rings which are in conformance with the manufacturer's bore and material recommendation for the intended service or grounding rings shall be an integral component of the flow meter.
C. Signal Transmitter: The microprocessor-based signal converter/transmitter shall have the following attributes:
1. Utilize DC pulse technique to drive flux-producing coils. 2. A minimum 16-digit LCD display for flow rate and totalized flow in engineering units (gpm or cfs). 3. Bi-directional flow indication with forward, reverse, and net non-volatile totalization. 4. An operator interface consisting of keypads which respond to English text entry. 5. Rated for NEMA 6 submergence conditions.
BC&A JVWCD METERS, GENERAL CENTRAL PIPELINE PROJECT PAGE 15075-2 6. Programmable parameters including meter size, full scale Q, magnetic field frequency, primary constant, time constant. Parameter adjustments shall be by keypad or non-intrusive means. 7. Self diagnostics and automatic data checking. 8. Protected terminals and fuses in a separate compartment which isolates field connection from electronics. 9. Produces a scaleable frequency output, 0 to 100 Hz. 10. Can tolerate ambient temperature operating limits of -20 to 140 degrees F (-29 to 60 degrees C). 11. Surface (wall) mountable, unless otherwise noted.
D. Calibration: Each magnetic flowmeter system shall be hydraulically calibrated prior to shipping in an ISO 9001 and NIST certified facility. A real-time computer generated printout of the actual calibration data indicating apparent and actual flows at 20 percent, 40 percent, 60 percent, 80 percent and 100 percent of the calibrated range shall be submitted to the ENGINEER prior to shipment of the meters to the project site. Provide all required field calibration equipment for magnetic flow meters.
E. Performance Requirements:
1. Accuracy - + 0.5 percent between 1.5 and 30 ft/sec + 5 percent at 0.15 ft/sec 2. Repeatability - 0.1 percent of reading 3. Pressure - to 30 psi 4. Power Supply - 120 VAC 5. Power Consumption - 20 watts or less 6. Output - 4-20 mA analog output 7. 48” Dia Flow Range - 0-75 cfs 8. 10” Dia Flow Range - 0-2,000 GPM
F. Features:
1. Ability to check zero alignment without stopping flow. 2. Capable of measuring bi-directional flow. 3. Low flow cut-off adjustable between 0.01 and 1 foot per second. Below selected value, output is driven to the zero flow rate signal level. 4. Non-volatile Totalizer. 5. Forward, Reverse, and Net Totals.
G. Manufacturers, No Equal
1. Endress-Hauser. ProMag 53W 2. Rosemount. 8750 Flowtube with remote transmitter
2.2 SPARE PARTS AND SPECIAL TOOLS
A. Furnish the spare parts listed in the individual meter sections. Spare parts shall be suitably packaged and labeled by part name and associated equipment number.
B. The CONTRACTOR shall furnish special tools suitably wrapped and identified for application. Special tools shall include substitute steel spools for each meter for
BC&A JVWCD METERS, GENERAL CENTRAL PIPELINE PROJECT PAGE 15075-3 maintenance purposes. Each spool shall be labeled to identify the associated meter including the meter identification number, size, and service.
PART 3 – EXECUTION
3.1 MANUFACTURER’S SERVICE REPRESENTATIVE
A. Erection and Startup Assistance: During erection and startup the obtain all necessary assistance from an experienced factory service representative to ensure a correct and first class installation, in accordance with the Manufacturer’s instructions, all at no increased cost to the OWNER.
B. INSPECTION AND TESTING REQUIREMENTS: After installation, obtain the services of an experienced factory service representative to assist, inspect, and test all meters for proper performance and installation, and to instruct OWNER’s personnel, all at no increased cost to the OWNER.
C. Instruction of OWNER’s Personnel: After completion of the installation and during startup of the WORK, instruct the OWNER’s personnel in the proper operation, maintenance and repair of all metering equipment. For this purpose, obtain the services of an experienced factory service representative, who shall spend not less than 4 hours on the site to fully instruct the OWNER’s operating personnel on all phases of its equipment, all at no increased cost to the OWNER.
3.2 INSTALLATION
A. The CONTRACTOR shall assemble and install equipment specified herein, in strict accordance with the Manufacturer’s published instructions, under the supervision of the Manufacturer’s representative, under the general review of the ENGINEER. All installations shall be accomplished by competent craftsmen in a workmanlike manner.
B. The meters shall be installed in easily accessible locations for ease of reading and maintenance and in conjunction with shut-off valves. Wherever possible, all meters shall be installed in such a way to provide the Manufacturer’s recommended straight approach and straight piping downstream. Where insufficient straight run of pipe is available, the CONTRACTOR shall require the Manufacturer to provide recommendations of how to utilize available straight pipe for best accuracy. All meters and shut-off valves shall be firmly supported from the structure or from the floor with approved supports. In-line meters shall be installed to provide full-line flow and not less than the Manufacturer’s recommended head at all times.
3.3 CLEANUP
A. After completion and testing of its WORK, the CONTRACTOR shall remove all debris from the site, clean all meters, controls, cabinets, and other metering appurtenances, to hand over each system in satisfactory operating condition.
BC&A JVWCD METERS, GENERAL CENTRAL PIPELINE PROJECT PAGE 15075-4 3.4 TESTING
A. Equipment shall be prepared for operational use in accordance with the Manufacturer’s instructions, including bench test and calibration, where required.
B. Each item shall be subjected to a factory test over the total range of capability of the equipment. Where applicable, tests shall be conducted in accordance with the Test Code of the standards of the Hydraulic Institute. The CONTRACTOR shall supply copies of factory test certifications.
3.5 ACCEPTANCE BY OWNER
A. Final acceptance of the equipment is contingent on satisfactory operation after installation.
END OF SECTION
BC&A JVWCD METERS, GENERAL CENTRAL PIPELINE PROJECT PAGE 15075-5
SECTION 15076
IDENTIFICATION FOR PLUMBING AND HVAC PIPING AND EQUIPMENT
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section includes the following mechanical identification materials and their installation:
1. Equipment markers. 2. Pipe markers.
1.3 SUBMITTALS
A. Product Data: For each type of product indicated.
1.4 QUALITY ASSURANCE
A. ASME Compliance: Comply with ASME A13.1, "Scheme for the Identification of Piping Systems," for letter size, length of color field, colors, and viewing angles of identification devices for piping.
1.5 COORDINATION
A. Coordinate installation of identifying devices with completion of covering and painting of surfaces where devices are to be applied.
B. Coordinate installation of identifying devices with location of access panels and doors.
C. Install identifying devices before installing acoustical ceilings and similar concealment.
PART 2 - PRODUCTS
2.1 EQUIPMENT IDENTIFICATION DEVICES
A. Equipment Markers: Engraved, color-coded laminated plastic. Include contact-type, permanent adhesive.
1. Terminology: Match schedules as closely as possible. 2. Data: a. Name and plan number. b. Equipment service.
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c. Design capacity. d. Other design parameters such as pressure drop, entering and leaving conditions, and speed. 3. Size: 2-1/2 by 4 inches for control devices, dampers, and valves; 4-1/2 by 6 inches for equipment.
2.2 PIPING IDENTIFICATION DEVICES
A. Manufactured Pipe Markers, General: Preprinted, color-coded, with lettering indicating service, and showing direction of flow.
1. Colors: Comply with ASME A13.1, unless otherwise indicated. 2. Lettering: Use piping system terms indicated and abbreviate only as necessary for each application length. 3. Pipes with OD, Including Insulation, Less Than 6 inches: Full-band pipe markers extending 360 degrees around pipe at each location. 4. Pipes with OD, Including Insulation, 6 inches and Larger: Either full-band or strip-type pipe markers at least three times letter height and of length required for label. 5. Arrows: Integral with piping system service lettering to accommodate both directions; or as separate unit on each pipe marker to indicate direction of flow.
B. Pretensioned Pipe Markers: Precoiled semirigid plastic formed to cover full circumference of pipe and to attach to pipe without adhesive.
C. Shaped Pipe Markers: Preformed semirigid plastic formed to partially cover circumference of pipe and to attach to pipe with mechanical fasteners that do not penetrate insulation vapor barrier.
D. Self-Adhesive Pipe Markers: Plastic with pressure-sensitive, permanent-type, self- adhesive back.
E. Plastic Tape: Continuously printed, vinyl tape at least 3 mils thick with pressure- sensitive, permanent-type, self-adhesive back.
1. Width for Markers on Pipes with OD, Including Insulation, Less Than 6 inches: 3/4-inch minimum. 2. Width for Markers on Pipes with OD, Including Insulation, 6 inches or Larger: 1- 1/2 inches minimum.
PART 3 - EXECUTION
3.1 APPLICATIONS, GENERAL
A. Products specified are for applications referenced in other related Sections. If more than single-type material, device, or label is specified for listed applications, selection is Installer's option.
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3.2 EQUIPMENT IDENTIFICATION
A. Install equipment markers with permanent adhesive on or near each major item of mechanical equipment.
1. Letter Size: Minimum 1/4-inch for name of units if viewing distance is less than 24 inches, 1/2-inch for viewing distances up to 72 inches, and proportionately larger lettering for greater viewing distances. Include secondary lettering two- thirds to three-fourths the size of principal lettering. 2. Data: Distinguish among multiple units, indicate operational requirements, indicate safety and emergency precautions, warn of hazards and improper operations, and identify units. 3. Locate markers where accessible and visible. Include markers for the following general categories of equipment: a. Electric unit heaters. b. Gas-fired unit heaters. c. Exhaust fans. d. Motorized dampers. e. Heat recovery units.
3.3 PIPING IDENTIFICATION
A. Install manufactured pipe markers indicating service on each piping system. Install with flow indication arrows showing direction of flow.
1. Pipes with OD, Including Insulation, Less Than 6 inches: Self-adhesive pipe markers. Use color-coded, self-adhesive plastic tape, at least 3/4-inch wide, lapped at least 1-1/2 inches at both ends of pipe marker, and covering full circumference of pipe. 2. Pipes with OD, Including Insulation, 6 inches and Larger: Self-adhesive pipe markers. Use color-coded, self-adhesive plastic tape, at least 1-1/2 inches wide, lapped at least 3 inches at both ends of pipe marker, and covering full circumference of pipe.
B. Locate pipe markers where piping is exposed in finished spaces; machine rooms; accessible maintenance spaces such as shafts, tunnels, and plenums; exterior nonconcealed locations and concealed ceiling spaces as follows:
1. Near major equipment items and other points of origination and termination.
END OF SECTION
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SECTION 15080 HVAC AND PLUMBING INSULATION
PART 1 - GENERAL
1.1 SUMMARY
A. This Section includes duct insulation.
1.2 SUBMITTALS
A. Product data for each type of mechanical insulation identifying k-value, thickness, jackets (factory and field applied) and accessories.
1.3 QUALITY ASSURANCE
A. Fire Performance Characteristics: Conform to the following characteristics for insulation including facings, cements, and adhesives, when tested according to ASTM E 84, by UL or other testing or inspecting organization acceptable to the authority having jurisdiction. Label insulation with appropriate markings of testing laboratory.
1. Interior Insulation: Flame spread rating of 25 or less and a smoke developed rating of 50 or less.
1.4 COORDINATION
A. Coordinate clearance requirements with piping Installer for piping insulation application, duct Installer for duct installation application, and equipment Installer for equipment insulation application. Before preparing piping and ductwork Shop Drawings, establish and maintain clearance requirements for installation of insulation.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. Manufacturers: Subject to compliance with requirements, provide products by one of the following:
1. Glass Fiber: a. CertainTeed Corporation. b. Knauf Fiberglass. c. Manville/Schuller. d. Owens-Corning Fiberglas Corporation.
2.2 GLASS FIBER
A. Material: Inorganic glass fibers, bonded with a thermosetting resin.
B. Jacket: All-service, factory-applied, laminated glass-fiber-reinforced, flame-retardant kraft paper and aluminum foil skrim backing having pressure sensitive self-sealing lap.
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C. Board: ASTM C 612, Class 2, semi-rigid jacketed board.
1. Thermal Conductivity: 0.23 verage maximum, at 75 deg F mean temperature. 2. Density: 3.0 pcf average maximum.
D. Blanket: ASTM C 553, Type I, Class B-2, jacketed flexible blankets.
Thermal Conductivity: 0.27 at compressed thickness, at 75 deg F mean temperature. 1. Density: 0.75lb/cu. Ft.
2.3 ACCESSORIES AND ATTACHMENTS
A. Bands: 3/4-inch wide, in one of the following materials compatible with jacket: 1. Aluminum: 0.007-inch thick. 2. 1/8” x 1/8”Rapid Penetrating point screws for non vapor barrier application.
B. Wire: 14 gauge nickel copper alloy, 16 gauge, soft-annealed stainless steel, or 160 gauge, soft-annealed galvanized steel.
C. Cupped Head Weld Pins- 1 ½” diameter cupped head, mild, annealed steel with zinc plating.
D. Corner Angles: 28 gauge, 1 inch by 1 inch aluminum, adhered to 2 inch by 2 inch kraft paper.
E. Anchor Pins: Capable of supporting 20 pounds each. Provide anchor pins and speed washers of sizes and diameters as recommended by the manufacturer for insulation type and thickness.
F. ASJ Tape: White vapor-retarder tape matching factory-applied jacket with acrylic adhesive, complying with ASTM C 1136 and UL listed.
1. Width: 3 inches. 2. Thickness: 11.5 mils. 3. Adhesion: 90 ounces force/inch in width. 4. Elongation: 2 percent. 5. Tensile Strength: 40 lbf/inch in width. 6. ASJ Tape Disks and Squares: Precut disks or squares of ASJ tape.
G. Foil/Skrim/Kraft Tape: Vapor barrier tape with rubber adhesive and UL listed and 25/20 rated.
1. Width: 2 inches. 2. Thickness: 3.7 mils. 3. Adhesion: 85 ounces force/inch in width. 4. Elongation: 5 percent. 5. Tensile Strength: 45 lbf/inch in width.
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PART 3 - EXECUTION
3.1 PREPARATION
A. Surface Preparation: Clean, dry, and remove foreign materials such as rust, scale, and dirt.
3.2 INSTALLATION, GENERAL
A. Refer to schedules at the end of this Section for materials, forms, jackets, and thicknesses required for each mechanical system.
B. Select accessories compatible with materials suitable for the service. Select accessories that do not corrode, soften, or otherwise attack the insulation or jacket in either the wet or dry state.
C. Install vapor barriers on insulated pipes, ducts, and equipment where indicated and defined in insulation service chart.
D. Apply insulation material, accessories, and finishes according to the manufacturer's printed instructions.
E. Seal joints and seams to maintain vapor barrier on insulation requiring a vapor barrier.
F. Seal penetrations for hangers, supports, anchors, and other projections in insulation requiring a vapor barrier.
G. Keep insulation materials dry during application and finishing.
H. Items Not Insulated: Unless otherwise indicated do not apply insulation to the following systems, materials, and equipment:
1. Flexible connectors for ducts and pipes. 2. Testing laboratory labels and stamps. 3. Nameplates and data plates. 4. Access panels and doors in air distribution systems.
3.3 DUCT INSULATION
A. Install block and board insulation as follows:
1. Adhesive and Band Attachment: Secure block and board insulation tight and smooth with at least 50 percent coverage of adhesive. Install bands spaced 12 inches apart. Protect insulation under bands and at exterior corners with metal corner angles. Fill joints, seams, and chipped edges with vapor barrier compound. Install metal corner angles on all outside corners to provide a neat finished appearance. 2. Speed Washers or Weld Pins Attachment: Secure insulation tight and smooth with speed washers or welded pin attachments. Space anchor pins 18 inches apart each way and 3 inches from insulation joints. Apply mastic to insulation in contact, open joints, breaks, punctures, and voids in insulation.
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B. Blanket Insulation: Install tight and smooth. Secure to ducts having long sides or diameters as follows:
1. 24 Inches and Larger: Anchor pins spaced 12 inches apart each way. 2. Overlap joints 3 inches. 3. Seal joints, breaks, and punctures with vapor barrier tape, matching jacket material.
3.4 INSULATION SCHEDULES
A. General: Abbreviations used in the following schedules include:
1. Materials: GF - Glass Fiber, FE - Flexible Elastomeric, CG - Cellular Glass, CS - Calcium Silicate, FPS - Fire Protection System.
B. Duct Systems:
FIELD INSULATION THICKNESS VAPOR APPLIED APPLICATION TYPE MATERIAL (INCHES) BARRIER JACKET OUTSIDE AIR DUCTS BLANKET GF 2 YES NONE FROM INTAKE TO HEAT RECOVERY UNIT CONNECTION EXHAUST DISCHARGE BLANKET GF 2 YES NONE AIR DUCTS FROM HEAT RECOVERY UNIT CONNECTION TO OUTLET SUPPLY DUCTS FROM BOARD GF 2 YES NONE HEAT RECOVERY UNIT WITH ASJ TO SUPPLY GRILLES EXHAUST DUCTS FROM BOARD GF 2 YES NONE HEAT RECOVERY UNIT WITH ASJ TO EXHAUST GRILLES
END OF SECTION
CTA ARCHITECTS ENGINEERS HVAC AND PLUMBING INSULATION JVWCD PAGE 15080 - 4 CENTRAL PIPELINE PROJECT
SECTION 15180 STRAINERS
PART 1 – GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall provide pipe strainers where indicated, complete and operable, in accordance with the Contract Documents.
B. Strainers shall be of ample size, with the perforations suitable for each individual service, and designed for easy cleaning and removal of the strainer basket.
1.2 CONTRACTOR SUBMITTALS
A. General: Submittals shall be in accordance with Section 01300 - Contractor Submittals.
B. Shop Drawings: Shop Drawings shall include construction details, sizes, dimensions, materials, and pressure ratings, in accordance with Section 11000 - Equipment General Provisions.
PART 2 – PRODUCTS
2.1 STRAINERS (METAL BODY)
A. Equipment Requirements: Strainers shall be of the wye-pattern or basket type, with flush connections, cast iron or bronze bodies, and screwed ends for sizes 3-inch and smaller, and flanged ends for sizes greater than 3-inch. They shall be designed for not less than 250 psi working pressure in sizes 3-inch and smaller, and 125 psi working pressure in sizes over 3-inch. Strainers shall be of the same size as the entering pipe and the screens shall have a free area of not less than 3 times the cross-sectional area of the pipe.
B. Screens: Unless otherwise indicated or required by the service fluid, the screens shall be constructed of type 316 stainless steel or monel construction, easily removable, with the following mesh or perforations:
Strainer Size Size of Perforations 1/4 - through 2-inch 20 mesh 2 1/2 through 5-inch 1/16-inch dia. or 3/64-inch 6 through 8-inch 1/8-inch dia over 8-inch 3/16-inch dia
C. Manufacturers, or Equal:
1. Armstrong - Yoshitake, Inc. 2. Fisher Controls Company 3. G. A. Industries, Inc.
BC&A STRAINERS JVWCD PAGE 15180-1 CENTRAL PIPLINE PROJECT 4. Mueller Steam Specialty 5. Watts Regulator Company
2.2 STRAINERS (PLASTIC BODY BASKET TYPE)
A. Equipment Requirements: Strainers shall be of the basket type, with flush connections, CPVC bodies, Viton O-ring seals, flanged connections. End connections shall be of the same size as supply pipe. All basket strainers shall have pressure release valve and safety pressure gauge. They shall be designed for the following working pressures:
2- to 8-inches 150 psi 10- to 12-inches 50 psi
B. Screen: The screens shall be of CPVC with a free area of 6 times the cross-sectional area of the pipe and 3/32-inch perforations for 1-inch and smaller and 1/8-inch perforations for strainers larger than 1-inch.
C. Flange to flange width of basket in-line with pipe shall not exceed 12-inches.
D. Manufacturers, no Equal:
1. Spears Manufacturing Company 2. Hayward Industrial Products, Inc.
2.3 STRAINERS (PLASTIC BODY Y-PATTERN TYPE)
A. Equipment Requirements: Strainers shall be of the Y-pattern type with removable screen, magnetic drain plug, cap, EPDM or Viton O-ring seal, and PVC body with flanged ends, rated for the following pressures at 73 degrees F:
1/2- to 2-inches 150 psi 1/2- to 2-inches 90 psi 3- to 4-inches 60 psi
B. Screen: The screens shall be of PVC with a free area of twice the cross-sectional area of the pipe and 1/32-inch perforations.
C. Manufacturers, or Equal:
1. Spears Manufacturing Company 2. ASAHI/AMERICA 3. Hayward Industrial Products, Inc.
PART 3 – EXECUTION
3.1 INSTALLATION
A. Unless otherwise indicated, strainers shall be provided ahead of any control valves, regulators, steam and condensate traps, and where indicated, and shall be preceded by shut-off valves.
BC&A – 02/09 STRAINERS TIMPANOGOS SPECIAL SERVICE DISTRICT PAGE 15180-2 2009 PLANT EXPANSION
B. Strainers shall be installed in accordance with the manufacturer's written instruction, in easily accessible locations for cleaning.
END OF SECTION
BC&A STRAINERS JVWCD PAGE 15180-3 CENTRAL PIPLINE PROJECT
SECTION 15194 NATURAL GAS PIPING
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section includes fuel gas piping within the Building. Products include the following:
1. Pipe, tube, fittings, and joining materials. 2. Protective pipe and fitting coating. 3. Piping specialties. 4. Specialty valves.
1.3 PROJECT CONDITIONS
A. Gas System Pressure: 0.5 psig or less.
B. Design values of fuel gas supplied for these systems are as follows:
1. Nominal Heating Value: 890 Btu/cu. ft. 2. Nominal Specific Gravity: 0.6.
1.4 SUBMITTALS
A. Product Data: For the following:
1. Specialty valves. Include pressure rating, capacity, settings, and electrical connection data of selected models. 2. Pressure regulators. Include pressure rating, capacity, and settings of selected models.
B. Welding certificates.
C. Field quality-control test reports.
D. Operation and Maintenance Data: For natural gas specialties and accessories to include in emergency, operation, and maintenance manuals.
1.5 QUALITY ASSURANCE
A. Welding: Qualify processes and operators according to ASME Boiler and Pressure Vessel Code: Section IX.
CTA ARCHITECTS ENGINEERS NATURAL GAS PIPING JVWCD PAGE 15194 - 1 CENTRAL PIPELINE PROJECT
B. Electrical Components and Devices: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use.
C. NFPA Standard: Comply with NFPA 54, "National Fuel Gas Code."
1.6 DELIVERY, STORAGE, AND HANDLING
A. Handling Flammable Liquids: Remove and legally dispose of liquids from drips in existing gas piping. Handle cautiously to avoid spillage and ignition. Notify fuel gas supplier. Handle flammable liquids used by Installer with proper precautions and do not leave on premises from end of one day to beginning of next day.
1.7 COORDINATION
A. Existing Utilities: Do not interrupt utilities serving facilities occupied by Owner or others unless permitted under the following conditions and then only after arranging to provide temporary utility services according to requirements indicated:
1. Notify Architect not less than two days in advance of proposed utility interruptions. 2. Do not proceed with utility interruptions without Architect's written permission.
B. Coordinate size and location of concrete bases. Cast anchor-bolt inserts into bases. Concrete, reinforcement, and formwork requirements are specified in Division 3.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. In other Part 2 articles where titles below introduce lists, the following requirements apply to product selection:
1. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, manufacturers specified.
2.2 PIPING MATERIALS
A. Refer to Part 3 "Piping Applications" Article for applications of pipe, tube, fitting, and joining materials.
2.3 PIPES, TUBES, FITTINGS, AND JOINING MATERIALS
A. Steel Pipe: ASTM A 53/A 53M; Type E or S; Grade B; black. Wall thickness of wrought- steel pipe shall comply with ASME B36.10M.
1. Malleable-Iron Threaded Fittings: ASME B16.3, Class 150, standard pattern, with threaded ends according to ASME B1.20.1.
CTA ARCHITECTS ENGINEERS NATURAL GAS PIPING JVWCD PAGE 15194 - 2 CENTRAL PIPELINE PROJECT
2. Steel Threaded Fittings: ASME B16.11, forged steel with threaded ends according to ASME B1.20.1. 3. Steel Welding Fittings: ASME B16.9, wrought steel or ASME B16.11, forged steel. 4. Unions: ASME B16.39, Class 150, malleable iron with brass-to-iron seat, ground joint, and threaded ends according to ASME B1.20.1. 5. Cast-Iron Flanges and Flanged Fittings: ASME B16.1, Class 125. 6. Joint Compound and Tape: Suitable for natural gas. 7. Steel Flanges and Flanged Fittings: ASME B16.5. 8. Gasket Material: Thickness, material, and type suitable for natural gas.
2.4 PIPING SPECIALTIES
A. Flexible Connectors: ANSI Z21.24, copper alloy.
B. Quick-Disconnect Devices: ANSI Z21.41, convenience outlets and matching plug connector.
2.5 SPECIALTY VALVES
A. Valves, NPS 2 and Smaller: Threaded ends according to ASME B1.20.1 for pipe threads.
B. Appliance Connector Valves: ANSI Z21.15 and CSA International listed.
1. Available Manufacturers:
a. American Valve Inc. b. B&K Industries, Inc. c. Brass Craft Manufacturing Co. d. Conbraco Industries, Inc.; Apollo Div. e. Jomar International Ltd. f. Mueller Co.; Mueller Gas Products Div. g. Robert Manufacturing Co. h. Watts Industries, Inc.; Water Products Div.
C. Gas Stops: Bronze body with AGA stamp, plug type with bronze plug and flat or square head, ball type with chrome-plated brass ball and lever handle, or butterfly valve with stainless-steel disc and fluorocarbon elastomer seal and lever handle; 2-psig minimum pressure rating.
D. Gas Valves, NPS 2 and Smaller: ASME B16.33 and CSA International-listed bronze body and 125 psig pressure rating.
1. Available Manufacturers:
a. Crane Valves. b. Grinnell Corp. c. Honeywell International Inc. d. Milwaukee Valve Company.
CTA ARCHITECTS ENGINEERS NATURAL GAS PIPING JVWCD PAGE 15194 - 3 CENTRAL PIPELINE PROJECT
e. Mueller Co.; Mueller Gas Products Div. f. NIBCO INC. g. Red-White Valve Corp. h. Watts Industries, Inc.; Water Products Div.
2. Tamperproof Feature: Include design for locking.
PART 3 - EXECUTION
3.1 EXAMINATION
A. Examine roughing-in for natural gas piping system to verify actual locations of piping connections before equipment installation.
1. Proceed with installation only after unsatisfactory conditions have been corrected.
3.2 PREPARATION
A. Close equipment shutoff valves before turning off fuel gas to premises or section of piping. Perform leakage test as specified in "Field Quality Control" Article to determine that all equipment is turned off in affected piping section.
3.3 SERVICE ENTRANCE PIPING
A. Extend fuel gas piping and connect to fuel gas distribution for service entrance to building.
1. Exterior fuel gas distribution system piping, service pressure regulator and service meter will be provided by gas utility.
B. Install dielectric fitting downstream from and adjacent to each service meter unless meter is supported from service-meter bar with integral dielectric fitting. Install shutoff valve downstream from and adjacent to dielectric fitting. Dielectric fittings are specified in Division 15 Section "Basic Mechanical Materials and Methods."
C. Install strainer upstream from each earthquake valve. Strainers are specified in Division 15 Section "Plumbing Specialties."
3.4 PIPING APPLICATIONS
A. Flanges, unions, transition, and special fittings with pressure ratings same as or higher than system pressure rating may be used in applications below, unless otherwise indicated.
B. Fuel Gas Piping, 2 psig or Less:
1. NPS 1/2 and Smaller: NPS 3/4 steel pipe, malleable-iron threaded fittings, and threaded joints.
CTA ARCHITECTS ENGINEERS NATURAL GAS PIPING JVWCD PAGE 15194 - 4 CENTRAL PIPELINE PROJECT
2. NPS 3/4 and NPS 1: Steel pipe, malleable-iron threaded fittings, and threaded joints.
3.5 VALVE APPLICATIONS
A. Appliance Shutoff Valves for Pressure 0.5 psig or Less: Appliance connector valve or gas stop.
B. Appliance Shutoff Valves for Pressure 0.5 to 2 psig: Gas stop or gas valve.
C. Piping Line Valves, NPS 2 and Smaller: Gas valve.
D. Valves at Service Meter, NPS 2 and Smaller: Gas valve.
3.6 PIPING INSTALLATION
A. Concealed Locations: Except as specified below, install concealed gas piping in airtight conduit constructed of Schedule 40, seamless, black steel pipe with welded joints. Vent conduit to outside and terminate with screened vent cap.
1. Above-Ceiling Locations: Gas piping may be installed in accessible spaces, subject to approval of authorities having jurisdiction, whether or not such spaces are used as plenums. Do not locate valves above ceilings. 2. In Partitions: Do not install concealed piping in solid partitions. Protect tubing from physical damage when installed inside partitions or hollow walls.
a. Exception: Tubing passing through partitions or walls.
3. In Walls: Gas piping with welded joints and protective wrapping specified in Part 2 "Protective Coating" Article may be installed in masonry walls, subject to approval of authorities having jurisdiction. 4. Prohibited Locations: Do not install gas piping in or through circulating air ducts, clothes or trash chutes, chimneys or gas vents (flues), ventilating ducts, or dumbwaiter or elevator shafts.
a. Exception: Accessible above-ceiling space specified above.
B. Drips and Sediment Traps: Install drips at points where condensate may collect. Include outlets of service meters. Locate where readily accessible for cleaning and emptying. Do not install where condensate would be subject to freezing.
1. Construct drips and sediment traps using tee fitting with bottom outlet plugged or capped. Use minimum-length nipple of 3 pipe diameters, but not less than 3 inches long, and same size as connected pipe. Install with space between bottom of drip and floor for removal of plug or cap.
C. Conceal pipe installations in walls, pipe spaces, utility spaces, above ceilings, below grade or floors, and in floor channels, unless indicated to be exposed to view.
D. Install fuel gas piping at uniform grade of 0.1 percent slope upward toward risers.
CTA ARCHITECTS ENGINEERS NATURAL GAS PIPING JVWCD PAGE 15194 - 5 CENTRAL PIPELINE PROJECT
E. Use eccentric reducer fittings to make reductions in pipe sizes. Install fittings with level side down.
F. Connect branch piping from top or side of horizontal piping.
G. Install unions in pipes NPS 2 and smaller, adjacent to each valve, at final connection to each piece of equipment, and elsewhere as indicated. Unions are not required on flanged devices.
H. Install corrugated, stainless-steel tubing system according to manufacturer's written instructions. Include striker plates to protect tubing from puncture where tubing is restrained and cannot move.
I. Install strainer on inlet of each line pressure regulator and automatic and electrically operated valve.
J. Install pressure gage downstream from each line pressure regulator. Pressure gages are specified in Division 15 Section "Meters and Gages."
K. Install flanges on valves, specialties, and equipment having NPS 2-1/2 and larger connections.
L. Install vent piping for gas pressure regulators and gas trains, extend outside building, and vent to atmosphere. Terminate vents with turned-down, reducing-elbow fittings with corrosion-resistant insect screens in large end.
3.7 JOINT CONSTRUCTION
A. Basic piping joint construction is specified in Division 15 Section "Basic Mechanical Materials and Methods."
B. Use materials suitable for fuel gas.
1. Brazed Joints: Make with brazing alloy with melting point greater than 1000 deg F. Brazing alloys containing phosphorus are prohibited.
C. Patch factory-applied protective coating as recommended by manufacturer at field welds and where damage to coating occurs during construction.
3.8 HANGER AND SUPPORT INSTALLATION
A. Install hangers for horizontal steel piping with the following maximum spacing and minimum rod sizes:
1. NPS 1 and Smaller: Maximum span, 96 inches; minimum rod size, 3/8 inch.
CTA ARCHITECTS ENGINEERS NATURAL GAS PIPING JVWCD PAGE 15194 - 6 CENTRAL PIPELINE PROJECT
3.9 CONNECTIONS
A. Drawings indicate general arrangement of fuel gas piping, fittings, and specialties.
B. Install piping adjacent to appliances to allow service and maintenance.
C. Connect piping to appliances using gas with shutoff valves and unions. Install valve upstream from and within 72 inches of each appliance. Install union downstream from valve.
D. Sediment Traps: Install tee fitting with capped nipple in bottom to form drip, as close as practical to inlet of each appliance using gas.
E. Ground equipment according to Division 16 Section "Grounding and Bonding."
1. Do not use gas pipe as grounding electrode.
F. Connect wiring according to Division 16 Section "Conductors and Cables."
3.10 LABELING AND IDENTIFYING
A. Equipment Nameplates and Signs: Install engraved plastic-laminate equipment nameplate or sign on or near each service meter, pressure regulator, and specialty valve.
1. Text: In addition to name of identified unit, distinguish between multiple units, inform operator of operational requirements, indicate safety and emergency precautions, and warn of hazards and improper operations. 2. Nameplates, pipe identification, and signs are specified in Division 15 Section "Mechanical Identification."
3.11 PAINTING
A. Use materials and procedures in Division 9 painting Sections.
B. Paint exterior pressure regulators, and specialty valves.
1. Color: Gray.
3.12 FIELD QUALITY CONTROL
A. Test, inspect, and purge piping according to NFPA 54 and requirements of authorities having jurisdiction.
B. Repair leaks and defects with new materials and retest system until satisfactory results are obtained.
C. Verify capacities and pressure ratings of service meters, pressure regulators, valves, and specialties.
CTA ARCHITECTS ENGINEERS NATURAL GAS PIPING JVWCD PAGE 15194 - 7 CENTRAL PIPELINE PROJECT
D. Verify correct pressure settings for pressure regulators.
E. Verify that specified piping tests are complete.
END OF SECTION
CTA ARCHITECTS ENGINEERS NATURAL GAS PIPING JVWCD PAGE 15194 - 8 CENTRAL PIPELINE PROJECT
SECTION 15200 VALVES, GENERAL
PART 1 -- GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall provide valves, actuators, and appurtenances, complete and operable, in accordance with the Contract Documents.
B. The provisions of this Section shall apply to all valves and valve actuators except where otherwise indicated. Valves and actuators in particular locations may require a combination of units, sensors, limit switches, and controls indicated in other Sections of the Specifications.
C. Where a valve is to be supported by means other than the piping to which it is attached, the Contractor shall obtain from the valve manufacturer a design for support and foundation. The design, including drawings and calculations sealed by an engineer, shall be submitted with the Shop Drawings. When the design is approved, the support shall be provided.
D. Unit Responsibility: A single manufacturer shall be made responsible for coordination of design, assembly, testing, and furnishing of each valve; however, the Contractor shall be responsible to the Owner for compliance with the requirements of each valve section. Unless indicated otherwise, the responsible manufacturer shall be the manufacturer of the valve.
E. Single Manufacturer: Where two or more valves of the same type and size are required, the valves shall be furnished by the same manufacturer.
F. The requirements of Section 11000 - Equipment General Provisions, apply to the WORK of this Section.
1.2 CONTRACTOR SUBMITTALS
A. Furnish submittals in accordance with Section 01300 - Contractor Submittals
B. Shop Drawings: Shop Drawings shall contain the following information:
1. Valve name, size, Cv factor, pressure rating, identification number (if any), and specification section number. 2. Complete information on valve actuator, including size, manufacturer, model number, limit switches, and mounting. 3. Cavitation limits for control valves. 4. Assembly drawings showing part nomenclature, materials, dimensions, weights, and relationships of valve handles, handwheels, position indicators, limit switches, integral control systems, needle valves, and control systems. 5. Data in accordance with Section 15201 - Electric Actuators for electric motor- actuated valves. 6. Complete wiring diagrams and control system schematics.
BC&A VALVES, GENERAL JVWCD PAGE 15200-1 CENTRAL PIPELINE PROJECT 7. Valve Labeling: A schedule of valves to be furnished with stainless steel tags, indicating in each case the valve location and the proposed wording for the label.
C. Technical Manual: The Technical Manual shall contain the required information for each valve.
D. Spare Parts List: A Spare Parts List shall contain the required information for each valve assembly, where indicated.
E. Factory Test Data: Where indicated, signed, dated, and certified factory test data for each valve requiring certification shall be submitted before shipment of the valve. The data shall also include certification of quality and test results for factory-applied coatings.
PART 2 -- PRODUCTS
2.1 PRODUCTS
A. General: Valves and gates shall be new and of current manufacture. Shut-off valves 6- inches and larger shall have actuators with position indicators. Gate valves 18-inches and larger or where chain wheel is required, shall be furnished with spur gear and hand wheel. Buried valves shall be provided with valve boxes and covers containing position indicators and valve extensions. Manual shut-off valves mounted higher than 7-feet above working level shall be provided with chain actuators.
B. Valve Actuators: Unless otherwise indicated, valve actuators shall be in accordance with Section 15201 - Electric Actuators.
C. Protective Coating: The exterior surfaces of all valves and the wet interior surfaces of ferrous valves of sizes 4-inches and larger shall be coated in accordance with Section 09900 - Coatings and Painting. The valve manufacturer shall certify in writing that the required coating has been applied and tested in the manufacturing plant prior to shipment, in accordance with these Specifications. Flange faces of valves shall not be epoxy coated.
D. Valve Labeling: Except when such requirement is waived by the construction Engineer in writing, a label shall be provided on shut-off valves and control valves except for hose bibbs and chlorine cylinder valves. The label shall be of 1/16-inch plastic or stainless steel, minimum 2-inches by 4-inches in size, as indicated in Section 15005 - Piping Identification Systems, and shall be permanently attached to the valve or on the wall adjacent to the valve as directed by the construction manager.
E. Valve Testing: As a minimum, unless otherwise indicated or recommended by the reference Standards, valves 3-inches in diameter and smaller shall be tested in accordance with manufacturer's standard and 4-inches in diameter and larger shall be factory tested as follows:
1. Hydrostatic Testing: Valve bodies shall be subjected to internal hydrostatic pressure equivalent to twice the water rated pressure of the valve. Metallic valves rating pressures shall be at 100 degrees F and plastic valves shall be 73 degrees, or at higher temperature according to type of material. During the hydrostatic test, there shall be no leakage through the valve body, end joints, or
BC&A VALVES, GENERAL JVWCD PAGE 15200-2 CENTRAL PIPELINE PROJECT shaft seals, nor shall any part of the valve be permanently deformed. The duration shall be sufficient time to allow visual examination for leakage. Test duration shall be at least 10 minutes. 2. Seat Testing: Valves shall be tested for leaks in the closed position with the pressure differential across the seat equal to the water rated pressure of the valve. The duration of test shall be sufficient time to allow visual examination for leakage. Test duration shall be at least 10 minutes. Leakage past the closed valve shall not exceed 1 fluid ounce per hour per inch diameter for metal seated valves and drop-tight for resilient seated valves. 3. Performance Testing: Valves shall be shop operated from fully closed to fully open position and reverse under no-flow conditions in order to demonstrate the valve assembly operates properly.
F. Certification: Prior to shipment, the Contractor shall submit for valves over 12-inches in size, certified, notarized copies of the hydrostatic factory tests, showing compliance with the applicable standards of AWWA, ANSI, or ASTM.
G. Valve Marking: Valve bodies shall be permanently marked in accordance with MSS SP25 - Standard Marking Systems for Valves, Fittings, Flanges, and Unions.
2.2 MATERIALS
A. General: Materials shall be suitable for the intended application. Materials in contact with potable water shall be listed as compliant with NSF Standard 61. Materials not indicated shall be high-grade standard commercial quality, free from defects and imperfections that might affect the serviceability of the product for the purpose for which it is intended. Unless otherwise indicated, valve and actuator bodies shall conform to the following requirements:
1. Cast Iron: Close-grained gray cast iron, conforming to ASTM A 48 - Gray Iron Castings, Class 30, or to ASTM A 126 - Gray Iron Castings for Valves, Flanges, and Pipe Fittings. 2. Ductile Iron: ASTM A 536 - Ductile Iron Castings, or to ASTM A 395 - Ferritic Ductile Iron Pressure-Retaining Castings for Use at Elevated Temperatures. 3. Steel: ASTM A 216 - Steel Castings, Carbon Suitable for Fusion Welding for High-Temperature Service, or to ASTM A 515 - Pressure Vessel Plates, Carbon Steel, for Intermediate- and Higher-Temperature Service. 4. Bronze: ASTM B 62 - Composition Bronze or Ounce Metal Castings, and valve stems not subject to dezincification shall conform to ASTM B 584 - Copper Alloy Sand Castings for General Applications. 5. Stainless Steel: Stainless steel valve and operator bodies and trim shall conform to ASTM A 351 - Steel Castings, Austenitic, for High-Temperature Service, Grade CF8M, or shall be Type 316 stainless steel. 6. PVC: Poly Vinyl Chloride materials for valve body, flanges, and cover shall conform to Cell Classification 12454. 7. CPVC: Chlorinated Poly Vinyl Chloride materials for valve body, flanges, and cover shall conform to Cell Classification 23447. 8. NSF Standard 14: Materials shall be listed for use in contact with potable water.
BC&A VALVES, GENERAL JVWCD PAGE 15200-3 CENTRAL PIPELINE PROJECT 2.3 VALVE CONSTRUCTION
A. Bodies: Valve bodies shall be cast, molded (in the case of plastic valves), forged, or welded of the materials indicated, with smooth interior passages. Wall thicknesses shall be uniform in agreement with the applicable standards for each type of valve, without casting defects, pinholes, or other defects that could weaken the body. Welds on welded bodies shall be done by certified welders and shall be ground smooth. Valve ends shall be as indicated, and be rated for the maximum temperature and pressure to which the valve will be subjected.
B. Valve End Connections: Unless otherwise indicated, valves 2-1/2 inches diameter and smaller may be provided with threaded end connections. Valves 3-inches and larger shall have flanged end connections.
C. Bonnets: Valve bonnets shall be clamped, screwed, or flanged to the body and shall be of the same material, temperature, and pressure rating as the body. The bonnets shall have provision for the stem seal with the necessary glands, packing nuts, or yokes.
D. Stems: Valve stems shall be of the materials indicated, or, if not indicated, of the best commercial material for the specific service, with adjustable stem packing, O-rings, Chevron V-type packing, or other suitable seal. Bronze valve stems shall conform to ASTM B 584, except that zinc content shall not exceed 16 percent.
E. Stem Guides: Stem guides shall be provided, spaced 10-feet on centers unless the manufacturer can demonstrate by calculation that a different spacing is acceptable. Submerged stem guides shall be 304 stainless steel.
F. Internal Parts: Internal parts and valve trim shall be as indicated for each individual valve. Where not indicated, valve trim shall be of Type 316 stainless steel or other best suited material.
G. Nuts and Bolts: Nuts and bolts on valve flanges and supports shall be in accordance with Section 05500 - Miscellaneous Metalwork.
2.4 VALVE ACCESSORIES
A. Valves shall be furnished complete with the accessories required to provide a functional system.
2.5 SPARE PARTS
A. The Contractor shall furnish the required spare parts suitably packaged and labeled with the valve name, location, and identification number. The Contractor shall also furnish the name, address, and telephone number of the nearest distributor for the spare parts of each valve. Spare parts are intended for use by the Owner, after expiration of the correction of defects period.
2.6 MANUFACTURERS
A. Manufacturer's Qualifications: Valve manufacturers shall have a successful record of not less than 5 years in the manufacture of the valves indicated.
BC&A VALVES, GENERAL JVWCD PAGE 15200-4 CENTRAL PIPELINE PROJECT
2.7 AIR VALVES
A. Air Release Valve ½ inch to 2 inches:
1. Suitable for water service, automatically exhaust small amounts of entrained air that accumulates in a system. In CLOSED position, seat against resilient seat to prevent water leakage. 2. Rated working pressure as shown on the Drawings, cast iron or ductile iron body and cover, stainless steel float and trim, NPT threaded inlet and outlet, built and tested to AWWA C512. 3. Interior of valve shall be fusion bonded epoxy lined. 4. Provide specially designed Low Pressure Air Release Valve where working pressure is less than 10 psi. 5. Manufacturers and Products: a) APCO Valve and Primer Corp.; Series 200A. b) Val-Matic Valve; Series 15A to 45.6 c) GA Industries, LLC; Series 900
B. Combination Air Release Valve 1 inch to 16 inches:
1. Suitable for water service, combines the operating features of both an air and vacuum valve and air release valve. Air and vacuum portion to automatically exhaust air during filling of system and allow air to re-enter during draining or when vacuum occurs. The air release portion to automatically exhaust entrained air that accumulates in system. 2. Valve single body or dual body, air release valve mounted on air and vacuum valve, isolation valve mounted between the dual valves. 1-inch through 3-inch valves with NPT threaded inlet and outlet, 4-inch and larger valves with ANSI Class flanged inlet and outlet to match pressure rating shown on Drawings. 3. Rated working pressure as shown on the Drawings, cast iron or ductile iron body and cover, stainless steel float and trim, built and tested to AWWA C512. 4. Interior of valve shall be fusion bonded epoxy lined. 5. Manufacturers and Products: a) APCO Valve and Primer Corp.; Series 1100A. b) Val-Matic Valve; Series 101/22 to 116/38 with integral isolation butterfly valve. c) GA Industries, LLC: Series; Series 950 with integral isolation butterfly valve.
PART 3 -- EXECUTION
3.1 VALVE INSTALLATION
A. General: Valves, actuating units, stem extensions, valve boxes, and accessories shall be installed in accordance with the manufacturer's written instructions and as indicated. Gates shall be adequately braced to prevent warpage and bending under the intended use. Valves shall be firmly supported to avoid undue stresses on the pipe.
B. Access: Valves shall be installed with easy access for actuation, removal, and maintenance and to avoid interference between valve actuators and structural members, handrails, or other equipment.
BC&A VALVES, GENERAL JVWCD PAGE 15200-5 CENTRAL PIPELINE PROJECT C. Valve Accessories: Where combinations of valves, sensors, switches, and controls are indicated, the Contractor shall properly assemble and install such items so that systems are compatible and operating properly. The relationship between interrelated items shall be clearly noted on Shop Drawing submittals.
END OF SECTION
BC&A VALVES, GENERAL JVWCD PAGE 15200-6 CENTRAL PIPELINE PROJECT SECTION 15201 VALVE AND GATE ACTUATORS
PART 1 -- GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall provide valve and gate actuators and appurtenances, complete and operable, in accordance with the Contract Documents.
B. The provisions of this Section shall apply to valves and gates except where otherwise indicated in the Contract Documents.
C. Unit Responsibility: The valve or gate manufacturer shall be made responsible for coordination of design, assembly, testing, and installation of actuators on the valves and gates; however, the Contractor shall be responsible to the Owner for compliance of the valves, gates, and actuators with the Contract Documents.
D. Single Manufacturer: Where 2 or more valve or gate actuators of the same type or size are required, the actuators shall be produced by the same manufacturer.
E. The requirements of Section 16050 - Electrical General Provisions apply to the Work of this Section.
1.2 CONTRACTOR SUBMITTALS
A. Furnish submittals in accordance with Section 01300 - Contractor Submittals and Section 15200 - Valves, General.
B. Shop Drawings: Shop Drawing information for actuators shall be submitted together with the valve and gate submittals as a complete package.
C. Calculations: Selection calculations showing dynamic seating and unseating torques versus output torque of actuator.
D. Technical Manuals: The Contractor shall furnish technical manuals for the valves, valve manual actuators, and valve electric motor actuators under one cover and in accordance with the requirements of Section 01300 – Contractor Submittals.
PART 2 -- PRODUCTS
2.1 GENERAL
A. Unless otherwise indicated, shut-off and throttling valves and externally actuated valves and gates shall be provided with manual or power actuators. The Contractor shall furnish actuators complete and operable with mounting hardware, motors, gears, controls, wiring, solenoids, handwheels, levers, chains, and extensions, as applicable. Actuators shall have the torque ratings equal to or greater than required for valve seating and dynamic torques, whichever is greater, and shall be capable of holding the valve in
BC&A VALVE AND GATE ACTUATORS JVWCD PAGE 15201-1 CENTRAL PIPLINE PROJECT any intermediate position between fully-open and fully-closed without creeping or fluttering. Actuator torque ratings for butterfly valves shall be determined in accordance with AWWA C504 - Rubber-Seated Butterfly Valves. Wires of motor-driven actuators shall be identified by unique numbers.
B. Manufacturers: Where indicated, certain valves and gates may be provided with actuators manufactured by the valve or gate manufacturer. .
C. Materials: Actuators shall be current models of the best commercial quality materials and be liberally-sized for the required torque. Materials shall be suitable for the environment in which the valve or gate is to be installed.
D. Actuator Mounting and Position Indicators: Actuators shall be securely mounted by means of brackets or hardware specially designed and sized for this purpose and be of ample strength. The word "open" shall be cast on each valve or actuator with an arrow indicating the direction to open in the counter-clockwise direction. Gear and power actuators shall be equipped with position indicators. Where possible, manual actuators shall be located between 48- and 60-inches above the floor or the permanent working platform.
E. Standard: Unless otherwise indicated and where applicable, actuators shall be in accordance with AWWA C 540 - Power-Actuating Devices for Valves and Slide Gates.
F. Functionality: Electric, pneumatic, and hydraulic actuators shall be coordinated with the power requirements of Division 16 and instrumentation equipment indicated in Section 17300 - Process Control and Instrumentation Systems.
G. Fasteners: Fasteners shall be in accordance with Section 05500 - Miscellaneous Metalwork.
H. Protective Coatings: Protective coatings shall be in accordance with Section 09900 - Coatings and Painting.
2.2 MANUAL ACTUATORS
A. General: Unless otherwise indicated, valves and gates shall be furnished with manual actuators. Valves in sizes up to and including 4-inches shall have direct acting lever or handwheel actuators of the manufacturer's best standard design. Larger valves and gates shall have gear-assisted manual actuators, with an operating pull of maximum 60 pounds on the rim of the handwheel. Buried and submerged gear-assisted valves, gates, gear-assisted valves for pressures higher than 250 psi, valves 30-inches in diameter and larger, and where so indicated, shall have worm gear actuators, hermetically-sealed water-tight and grease-packed. Other valves 6-inches to 24-inches in diameter may have traveling nut actuators, worm gear actuators, spur or bevel gear actuators, as appropriate for each valve.
B. Buried Valves: Unless otherwise indicated, buried valves shall have extension stems to grade, with square nuts or floor stands, position indicators, and cast-iron or steel pipe extensions with valve boxes, covers, and operating keys. Where so indicated, buried valves shall be in cast-iron, concrete, or similar valve boxes with covers of ample size to
BC&A VALVE AND GATE ACTUATORS JVWCD PAGE 15201-2 CENTRAL PIPLINE PROJECT allow operation of the valve actuators. Covers of valve boxes shall be permanently labeled as required by the local Utility Company or the Engineer. Wrench nuts shall comply with AWWA C 500 - Metal - Seated Gate Valves for Water Supply Service.
C. Chain Actuator: Manually-activated valves with the stem located more than 7-feet above the floor or operating level shall be provided with chain drives consisting of sprocket-rim chain wheels, chain guides, and operating chains provided by the valve manufacturer. The wheel and guide shall be of ductile iron, cast iron, or steel, and the chain shall be hot-dip galvanized steel or stainless steel, extending to 5-feet 6-inches above the operating floor level. The valve stem of chain-actuated valves shall be extra strong to allow for the extra weight and chain pull. Hooks shall be provided for chain storage where chains interfere with pedestrian traffic.
D. Floor Stands: Valve actuator floor stands shall be cast iron or fabricated steel pedestals. The centerline of the actuator shall be approximately 42 to 48 inches above the base of the pedestal.
E. Floor Boxes: Hot dip galvanized cast iron or steel floor boxes and covers to fit the slab thickness shall be provided for operating nuts in or below concrete slabs. For operating nuts in the concrete slab, the cover shall be bronze-bushed.
F. Tee Wrenches: Buried valves with floor boxes shall be furnished with 2 operating keys or 1 key per 10 valves, whichever is greater. Tee wrenches sized so that the tee handle will be 2 to 4 feet above ground, shall fit the operating nuts.
G. Manual Worm Gear Actuator: The actuator shall consist of a single or double reduction gear unit contained in a weather-proof cast iron or steel body with cover and minimum 12-inch diameter handwheel. The actuator shall be capable of 90 degree rotation and shall be equipped with travel stops capable of limiting the valve opening and closing. The actuator shall consist of spur or helical gears or worm gearing. The gear ratio shall be self-locking to prevent "back-driving." The spur or helical gears shall be of hardened alloy steel and the worm gear shall be alloy bronze. The worm gear shaft and the handwheel shaft shall be of 17-4 PH or similar stainless steel. Gearing shall be accurately cut with hobbing machines. Ball or roller bearings shall be used throughout. Output shaft end shall be provided with spline to allow adjustable alignment. Actuator output gear changes shall be mechanically possible by simply changing the exposed or helical gearset ratio without further disassembly of the actuator. Gearing shall be designed for a 100 percent overload. The entire gear assembly shall be sealed weatherproof.
H. Traveling-Nut Actuator: The actuator shall consist of a traveling-nut with screw (Scotch yoke) contained in a weatherproof cast iron or steel housing with spur gear and minimum 12-inch diameter handwheel. The screw shall run in 2 end bearings, and the actuator shall be self-locking to maintain the valve position under any flow condition. The screw and gear shall be of hardened alloy steel or stainless steel, and the nut and bushings shall be of alloy bronze. The bearings and gear shall be grease-lubricated by means of nipples. Gearing shall be designed for a 100 percent overload.
BC&A VALVE AND GATE ACTUATORS JVWCD PAGE 15201-3 CENTRAL PIPLINE PROJECT I. Schedule for Manual Actuator Types: For a complete schedule of manual actuators required on project valves (4” diameter and larger), see Contract Drawing GM-1 and GM-02.
2.3 ELECTRIC MOTOR ACTUATORS
A. General
1. Equipment Requirements: Where electric motor actuators are indicated, an electric motor-actuated valve control unit shall be attached to the actuating mechanism housing by means of a flanged motor adapter piece. 2. Gearing: The motor actuator shall include the motor, reduction gearing, reversing starter, torque switches, and limit switches in a weather-proof NEMA 4 assembly. The actuator shall be a single or double reduction unit consisting of spur or helical gears and worm gearing. The spur or helical gears shall be of hardened alloy steel, and the worm gear shall be alloy bronze. Gearing shall be accurately cut with hobbing machines. Power gearing shall be grease- or oil- lubricated in a sealed housing. Ball or roller bearings shall be used throughout. Actuator output speed changes shall be mechanically possible by simply removing the motor and changing the exposed or helical gearset ratio without further disassembly of the actuator. 3. Starting Device: Except for modulating valves, the unit shall be so designed that a hammer blow is imparted to the stem nut when opening a closed valve or closing an open valve. The device should allow free movement at the stem nut before imparting the hammer blow. The actuator motor must attain full speed before stem load is encountered. 4. Switches a. Switches: Limit switches shall be furnished to sense valve position at each end of travel. Limit switch adjustment shall not be altered by manual operation. One set of normally open and one set of normally closed contacts will be furnished at each end of travel. Contacts shall be of sliver and capable of reliably switching the source power from the control system as shown on the drawings. An electronic torque sensor shall be furnished. The torque limit may be adjusted from 40 to 100 percent of rating in 1 percent increments. The motor shall be de- energized if the torque limit is exceeded. A boost function shall be included to prevent torque trip during initial valve unseating, and a “jammed valve” protection feature with automatic retry sequence shall be incorporated to de-energize the motor if no movement occurs. b. The actuator shall be wired in accordance with the schematic diagram. Wiring for external connections shall be connected to marked terminals. Two conduit connections shall be provided in the enclosing case. A calibration tag shall be mounted near each switch correlating the dial setting to the unit output torque. Switches shall not be subject to breakage or slippages due to over-travel. Limit switches shall be of the heavy-duty open contact type with rotary wiping action. 5. Handwheel Operation: A permanently attached handwheel shall be provided for emergency manual operation. The handwheel shall not rotate during electrical operation. The maximum torque required on the handwheel under the most adverse conditions shall not exceed 60 lb.ft, and the maximum force required on
BC&A VALVE AND GATE ACTUATORS JVWCD PAGE 15201-4 CENTRAL PIPLINE PROJECT the rim of the handwheel shall not exceed 60 lb. An arrow and either the word "open" or "close" shall be cast or permanently affixed on the handwheel to indicate the appropriate direction to turn the handwheel. A clutch lever shall be provided to put actuator into handwheel operation. Valves with electric motor actuators having stems more than 7-feet above the floor shall be provided with chain activator handwheels. The clutch lever shall be provided with a cable secured to the chain to allow disengagement for manual operation. 6. Motor: The motor shall be of the totally enclosed, non-ventilated, high-starting torque, low-starting current type for full voltage starting. It shall be suitable for operation on the power source based on the actuator chart and valve schedule on Contract Drawing GM-2 and GM-3, and have Class F insulation and a motor frame with dimensions in accordance with the latest revised NEMA MG Standards. The observed temperature rise by thermometer shall not exceed 55 degrees C above an ambient temperature of 40 degrees C when operating continuously for 15 minutes under full rated load. With a line voltage ranging between 10 percent above to 10 percent below the rated voltage, the motor shall develop full rated torque continuously for 15 minutes without causing the thermal contact protective devices imbedded in the motor windings to trip or the starter overloads to drop-out. Bearings shall be of the ball type, and thrust bearings shall be provided where necessary. Bearings shall be provided with suitable seals to confine the lubricant and prevent the entrance of dirt and dust. Motor conduit connections shall be watertight. Motor construction shall incorporate the use of stator and rotor as independent components from the valve operation such that the failure of either item shall not require actuator disassembly or gearing replacement. . Two Class B thermal contacts or solid state thermistors imbedded within the motor windings shall be provided to protect against over- temperature damage. The motor shall be provided with a space heater suitable for operation on 120 volt, single phase, 60 Hz circuit unless the entire actuator is a hermetically sealed, non-breathing design with a separately sealed terminal compartment which prevents moisture intrusion. Each electric motor actuator shall be provided with a local disconnect switch or circuit breaker to isolate power from the motor and controller during maintenance activities. 7. Open/Close Operating Speed: Size open-close/throttling service valve motors for one complete OPEN-CLOSE-OPEN cycle no less than once every 10 minutes unless otherwise indicated elsewhere in the specifications. 8. Schedule for Electric AC Actuator Type: For a complete schedule of electric actuators required on project valves (4” diameter and larger), see Contract Drawing GM-2 and GM-3.
B. Electric Motor Actuators (AC Reversing (Open / Close) Control Type)
1. General: Where indicated, electric motor actuators shall be the AC reversing type complete with local control station with open / stop / close and local/off/remote selector switches on the actuator local control station. 2. Actuator Appurtenances: The actuator for each valve shall be provided with a padlockable disconnect switch, open and closed status lights, open, close and lockout stop pushbuttons, a local/off/remote selector switch, and other devices indicated. The disconnect switches in certain applications are required to be located remotely from the actuator body itself, as shown on the Contract Drawings. The local control station may also be provided as an integral part of the actuator or
BC&A VALVE AND GATE ACTUATORS JVWCD PAGE 15201-5 CENTRAL PIPLINE PROJECT remotely as otherwise indicated or required to permit operation by a person at floor elevation and within sight of the valve actuator. The Contractor shall provide conduit and wiring between the actuator controls and the valve actuator for these applications. 3. Starter: The starter shall be a suitably sized amperage rated reversing starter with its coils rated for operation on Contract Drawing GM-2 and GM-3. A control power transformer shall be included to provide a 120 volt source, unless otherwise indicated. The starter shall be equipped with 3 overload relays of the automatic reset type. Its control circuit shall be wired as indicated. The integral weatherproof compartment shall contain a suitably sized 120 volt ac, single phase, 60 Hz space heater to prevent moisture condensation on electrical components. A local power disconnect switch shall be provided with each actuator. A close-coupled, padlockable switch shall be provided with each actuator. 4. Local Control Station: Each actuator shall be provided with a local control station with the valve actuator assembly. The station shall include open, close, and stop push buttons, and a local/remote selector switch. 5. Manufacturers: a. Rotork, IQ with worm gear, or IQT as appropriate for valve size. b. Limitorque, MX with PT worm gear, or QX as appropriate for valve size. c. No “Or-Equals” allowed.
PART 3 -- EXECUTION
3.1 SERVICES OF MANUFACTURER
A. Field Adjustments: Field representatives of manufacturers of valves or gates with pneumatic, hydraulic, or electric actuators shall adjust actuator controls and limit- switches in the field for the required function.
3.2 INSTALLATION
A. Valve and gate actuators and accessories shall be installed in accordance with Section 15200 - Valves, General. Actuators shall be located to be readily accessible for operation and maintenance without obstructing walkways. Actuators shall not be mounted where shock or vibrations will impair their operation, nor shall the support systems be attached to handrails, process piping, or mechanical equipment.
B. Inspection, Startup, and Field Adjustment: An authorized representative of the manufacturer shall visit the Site and witness the following:
1. Installation of the equipment for not less than two (1) Work Days 2. Inspection, checking, and adjusting the equipment for not less two (1) Work Days. 3. Startup and field-testing for proper operation for not less than two (1) Work Days.
C. Instruction of Owner's Personnel: The authorized service representative shall visit the Site for not less than 1 Days to instruct the Owner's personnel in the operation and
BC&A VALVE AND GATE ACTUATORS JVWCD PAGE 15201-6 CENTRAL PIPLINE PROJECT maintenance of the equipment including step-by-step troubleshooting procedures with necessary test equipment.
END OF SECTION
BC&A VALVE AND GATE ACTUATORS JVWCD PAGE 15201-7 CENTRAL PIPLINE PROJECT
SECTION 15202 BUTTERFLY VALVES
PART 1 -- GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall provide butterfly valves and appurtenances, complete and operable, in accordance with the Contract Documents.
B. The requirements of Section 15200 - Valves, General apply to this Section.
C. The requirements of Section 15201 - Electric Actuators apply to this Section.
D. Valves shall be of the body type, pressure class, end joint, and actuator type as indicated on the valve schedules on Contract Drawing GM-2 and GM-3.
1.2 QUALIFICATION REQUIREMENTS
A. The valve manufacturer shall have manufactured waterworks double eccentric butterfly valve for at least 10 years. At the Owner’s request, submit at least 10 of the manufacturer’s butterfly valves installation of comparable size and complexity to units indicated in this Section or a project similar in size and technical requirements.
The list shall include the following information: 1. Name of facility, owner of facility, contract name, addresses and telephone number.
2. Pressure class.
3. Model number and size.
4. Name, location and contact information of local representative.
B. Published manufacturers literature showing the valve is intended for sale into the water market and typical application of the project. Only valves specifically designed for high velocity and continuous pressurized waterworks applications will be accepted. General service or industrial valves will not be accepted.
C. Butterfly Valves shall have undergone FEA (Finite Element Analysis) to verify structural stress and deformation analysis as well as dynamic modal analysis and transient dynamic response. On more complicated and larger size applications, the owner reserves the right to review the manufacturers computational design output. Where a critical threshold headloss is communicated and required, CFD modeling shall be available.
D. The manufacturer shall demonstrate structured compliance to a repeatable build design and shall be ISO 9000 certified.
BC&A BUTTERFLY VALVES JVWCD PAGE 15202-1 CENTRAL PIPELINE PROJECT E. Valve manufacturer shall demonstrate a commitment to continuous improvement and quality control of their products. As such they shall have an “in use” and working in- house R&D lab. Valve testing shall be suitable for water hydraulic tests for sizes to a minimum of 12 inches. Photo documentation may be required.
1.3 CONTRACTOR SUBMITTALS
A. Furnish submittals in accordance with Section 15200.
B. Shop Drawings
1. Complete Shop Drawings of butterfly valves and actuators. 2. Drawings showing valve port diameter complete with dimensions, part numbers, and materials of construction. 3. Certification of proof-of-design test from the valve manufacturer. 4. Certification: Obtain written certification from the butterfly valve manufacturer, addressed to the Owner, stating that the butterfly valves and the valve operators will efficiently and thoroughly perform the required functions in accordance with these Specifications and as shown, and that the manufacturer accepts joint responsibility with the Contractor for coordination of all butterfly valves and valve operators, including motors, drives, controls, and services required for proper installation and operation of the completely assembled and installed units. The Contractor shall submit all such certificates to the construction manager. 5. Technical Manuals: Furnish technical manuals for the butterfly valves, manual operators, and electric motor valve operators under one cover and in accordance with the requirements of Section 01300 - Contractor Submittals. 6. Valve Labeling: Submit a schedule of butterfly valves to be labeled indicating in each case the valve location and the proposed wording for the label. 7. Field Procedures: Written instructions for field procedures for erection, adjustments, inspection, and testing shall be provided prior to delivery of the butterfly valves and valve operators.
1.4 QUALITY ASSURANCE
A. FACTORY TESTS
a. General: Inspection shall be made and tests performed at the manufacturer's facilities on the valves listed in this Subsection.
i. Submit test reports to the ENGINEER. Test reports shall include all factory and field required tests showing each valve is in conformance.
ii. Notice of each type of valve test shall be given to the ENGINEER no later than 14 days prior to the scheduled tests.
b. The CONTRACTOR shall perform factory tests in the following sequence with valve and actuator completely assembled as a unit.
i. Valve Body Hydrostatic Test: The test shall be performed with the valve positioned vertically as if installed in a horizontal pipeline, with both flanged ends bulkheaded and the disc in a slightly open position.
BC&A BUTTERFLY VALVES JVWCD PAGE 15202-2 CENTRAL PIPELINE PROJECT Apply internal hydrostatic pressure twice the pressure rating of the valve to the inside of the valve. With the disc in the slightly open position and both flanges bulkheaded, water shall be allowed to enter and completely fill the cavity between both flanged ends; then compressed air or high-pressure water shall be applied through one of the bulkheads into the cavity supplying up to and maintaining the test pressure for a 5 minute test duration. During the hydrostatic test, there shall be no leakage through any portion of the valve, the metal, end flange joints or the valve shaft seal, and there shall be no permanent deformation of any valve component.
ii. Valve Shutoff Leak Test: All valves shall initially be tested per section 5.2 of ANSI/AWWA C504. Unless otherwise noted, all valves will be leak tested in both flow directions. A secondary test shall be performed with the valve positioned as if installed in a horizontal pipeline, and with one flanged end bulkheaded and the disc in the fully closed position. The test for valves shall be performed at a differential pressure equal to the pressure rating of the valve with the body flanges in a vertical plane and one end flange bulkheaded. The test shall be the same for valves larger than 72”, except the differential pressure shall be equal to 100% of the design pressure. With the disc in the closed position, water shall be allowed to enter and completely fill the cavity between the disc and bulkheaded flange, and then compressed air or high- pressure water applied through the bulkheaded flange into the cavity, supplying up to and maintaining the test pressure for a 5-minute test duration. The entire surface of the valve disc shall be visible. There shall be no indication of any water or air leaks during the test period. Unless specifically noted, this test shall be performed in both flow directions.
iii. Valve Actuator and Operations Test: Manually Actuated Valves: The torque required on the AWWA nut to unseat the valve under a differential pressure of 150 psi shall be recorded. Recording may be performed at the completion of the valve shutoff leak test by using a torque wrench on the AWWA nut before the pressure is released. The valve completely assembled with the actuator shall be manually operated two complete cycles, from the fully open to the fully closed position, under a no-flow condition to show smooth operation. At the end of the first cycle, 300 foot-pounds of input torque shall be applied to the AWWA nut for 15 seconds at both fully open and fully closed positions. No signs of permanent deformation or binding shall be evident. The valve shall be completely cycled a second time after the torque test. Over the full travel of the actuator, during all cycles, there shall be no sign of binding, scraping, misalignment of parts, permanent deformation, or other defects. Actuator stops shall be adjusted so that the valve disc will travel 90 degrees, plus or minus one-half degree, from the closed position to the fully open position and shall be 90 degrees, plus or minus one-half degree, to the flange face when fully open.
BC&A BUTTERFLY VALVES JVWCD PAGE 15202-3 CENTRAL PIPELINE PROJECT c. Protective Coating Testing: All valves 48 inch and larger shall be tested for coating thickness and porosity. Porosity shall be tested using the high voltage spark method. Test shall be taken at all locations with critical focus around seat and seal. Coating thickness measurements at raised cast lettering may be visual. Results and validation shall be signed and dated.
B. FIELD TESTS
1. Field Tests: An authorized service representative of the manufacturer shall visit the site for a minimum of one service day for each two valves which are electrically, pneumatically or hydraulically actuated. They shall sign and certify in writing that the equipment and controls have been properly installed, tested and readied for operation.
Performance tests shall be made on all completely installed valves as follows: a. Butterfly Valves, 16-Inch and larger:
i. Each valve shall be operated 3 times from fully closed to fully opened position, and the reverse, under a no-flow condition.
b. Valves shall be hydrostatically tested at the same time that the adjacent pipeline is tested. Joints shall show no visible leakage. Repair any joints that show signs of leakage prior to final acceptance. If there are any special parts of control systems or operators that might be damaged by the pipeline test, they shall be properly protected. Repair any damage caused by the testing.
c. If possible a leak test will be conducted to verify that bubble tight shut-off has been achieved in both flow directions with operating pressure on one side of the disc and atmospheric pressure on the other. The owner reserves the right to field verify that valve leakage is zero.
d. Failure by the OWNER to inspect or witness tests at the manufacturer's plant shall not be construed as waiving inspection upon delivery.
PART 2 -- PRODUCTS
2.1 BUTTERFLY VALVES 4-INCH AND LARGER – CLASS 150B AND 250B
A. General: The butterfly valve shall be designed expressly for waterworks applications and shall be of the double offset design whereby the elastomeric seal is not compressed with the valve in the open position. Zero, single and API based triple offset butterfly valve designs are not acceptable. Butterfly valves for water working pressures up to 150 psi shall conform to ANSI/AWWA C504 Class 150B except that the valves rated working pressure shall be 250 psi excluding safety factors. Butterfly valves for water working pressures greater than 250 psi shall conform to the design requirements of ANSI/AWWA C-504, Class 250B but shall have a minimum of 350 psi working pressure and shall be subject to the following requirements. Valves shall be of the size and class indicated in
BC&A BUTTERFLY VALVES JVWCD PAGE 15202-4 CENTRAL PIPELINE PROJECT the valve schedule or in the plans. All valves unless noted otherwise, shall be sized for bi-directional water service, full rated pressure and a line velocity of 16 feet per second and suitable for higher linebreak velocities of 50 fps. Lifting lugs will be provided for all valves 24” and larger. B. Flanges: Class 150B flanged valves shall have ANSI B16.1 Class 125-pound flanges. Class 250B flanged valves shall comply with ANSI B16.1 Class 250 up through 48-inch unless otherwise noted or if mating to ductile iron pipe. Above 48-inch, flange outside diameter, number of bolts, diameter of bolt circle, and diameter of bolts shall comply with ANSI/AWWA C 207 Class E and the flange thickness shall be designed in accordance with ASME Section VIII, flange design requirements. C. Body: Valve bodies shall be ductile iron, ASTM A536 65-45-12 or A536 60-40-18. Cast gray iron is not allowed due to near zero elongation and as it vulnerable to shear stress. The valve body shall include integrally cast support feet top and bottom. It shall be mechanically equipped with a fastened stainless steel stamped or engraved tag indicating manufacturer and reference build data. Valves 54 inch and larger shall include two tags diametrically opposed. The valve build data shall be made available upon request by the customer and shall be retained by the manufacturer for no less than 70 years unless noted longer. The entire valve body and flanges shall be epoxy corrosion coat protected except for the valve shaft bores. D. Disc: The disc shall be ductile iron ASTM A536 65-45-12 or ASTM A536 60-40-18. The entire disc and all its wetted surfaces shall be coated without exception. The disc’s elastomeric seal retainer shall be 304 or 316 stainless steel. Neither bronze nor carbon steel is acceptable. Both the disc and elastomeric seal retainer shall have recesses designed to retain a dual shouldered seal under extreme localized velocities, at full differential opening and/or linebreak closing. The disc shall be mechanically fastened to the valve shaft using tangential stainless steel shaft pins of type 316 or higher alloy. Disc pins shall extend completely through the valve and shall be mechanically fastened. The disc shall be completely coated except for the disc shaft bores. E. Shaft: Valve shafts shall be dual stub shafts of stainless steel ASTM A276 Type 316, 304 or 420. The valve shaft material and thickness shall be suitable for the applications pressure and velocity without the use of its safety factors. Shafts may not be turned down to fit drive splines without accompanying torsional strength reduction calculations and its effect on the safety factor. F. Elastomeric Seal and Seal Ring: Valve seals shall be EPDM, secured to a completely coated valve disc by a 304 or 316 stainless steel, continuous non-segmented seal ring and secured by 316 stainless steel fasteners. The seal shall not scallop, cold flow or tear at localized velocities less than 300 fps. The elastomeric seal shall not be penetrated by fasteners. The valve shall be bi-directionally leak free. The elastomeric seal shall be double shouldered and extend no greater than 0.25 inches past the disc edge to seat the valve. The seal shall be designed to flex in either flow direction. There shall be a small gap on both sides of seal which will allow for pipeline pressurized media to further expand the seal against the metallic seat- the higher the differential pressure or velocity. The elastomeric seal shall be field replaceable and adjustable in line. It shall not require special skills or tools to replace the seat. With access to the seat retaining bolts, the seat removal, replacement and readiness for service must be able to be accomplished in a maximum of 3 hours for all size valves. Seat methods which do not comply or use either irreplaceable vulcanized seals or which use hardened epoxy or grout in a dovetailed groove are not acceptable.
BC&A BUTTERFLY VALVES JVWCD PAGE 15202-5 CENTRAL PIPELINE PROJECT G. Metallic Seat: The metallic valve seat shall be located in the valve body. It shall be a highly wear resistant stainless steel alloy. There shall be no gap between the valve body and metallic body seat and consequently no potential for corrosion or lifting of the seat. The seat shall be applied through a high alloy weld overlay process. Metallic seats shall not be mechanically retained by fasteners. H. Shaft Seals: Shaft seals shall not need periodic manual adjustment. They shall be multi-oring seals protecting both the OD and ID of the shaft bearings. They shall prevent pressurized system water from entering the uncoated valve disc hub and valve body shaft bore. The valve shaft shall remain non-wetted and unpressurized. The non-wetted shaft shall allow the actuator to be removed without dewatering the pipeline. It shall prevent debris and system pressurized water from entering into the uncoated valve body shaft bore. It shall prevent waters or contaminated media, external to the valve, from entering through the valve shaft under vacuum/ negative pressure conditions in the pipeline such as at line break. It shall additionally prevent an ingress breach where external hydrostatic forces exceed pipeline pressures such as in dewatered pipelines. Neither manual pulldown packing glands nor braided packing are allowed. The outer shaft seals shall be a replaceable cartridge type, bolted to the valve body. Packing shall not be held in place with an adapter plate or by the valve actuator. I. Shaft Bearings: Valve shaft bearings shall be corrosion resistant, self-lubricating sleeve type made of bronze, stainless steel or stainless steel backed PTFE. Bearing choice and consequent bearing friction shall be correctly added to valve input torque requirements. J. Strength: The proportion and dimensions of all parts of the valve and actuator shall be designed to withstand, without failure, the stresses occurring under the testing and operating conditions. The maximum allowable stress in any material shall not exceed 1/5 of the ultimate tensile strength or 1/3 of the minimum yield strength. Class 150B valves shall be rated to and shall receive a pressure test of 250 psi and Class 250B valves shall be rated to and shall receive a pressure test of 350 psi applied to one side of the disc with zero pressure applied to the other side of the disc while in the closed position, without damage or permanent deformation to any part of the valve, seat, disc or shaft. The valve shall be capable of withstanding such pressures in both directions. K. Safety Disc Pinning: Where noted herein, where noted on the plans or in the bid documents, an integrated safety locking device shall be incorporated. The valve shall have an externally lockable disc in the closed position. Calculations shall be provided to verify that the disc cannot rotate even with the full stall output torque of the actuator. The disc shall remain in the zero leak sealed closed position even if the entire actuator is removed for safety or maintenance. With the actuator and or the adapter plate removed, the valve will not leak through the stem. The locking device shall be handwheel operated; stainless steel wetted construction, pad lockable and suitable for lockout/tag out safety procedures. L. Manual Actuators: Actuators shall conform to Section 15201 – Valve and Gate Actuators and to ANSI/AWWA C 540, subject to the following requirements. All actuators shall be self-locking and shall hold the valve disc in the closed, open and any intermediate position without creeping or fluttering. All actuators shall incorporate a mechanical stop- limiting device to prevent over travel of the disc. Unless direct buried or otherwise indicated, all manually actuated butterfly valves shall be equipped with a handwheel and external position indicator. The number of turns for direct buried valves shall be a minimum of 1.4 times the nominal valve size with no fewer than 25 turns. The valve manufacturer shall be responsible for mounting and testing the actuator. Screw-type
BC&A BUTTERFLY VALVES JVWCD PAGE 15202-6 CENTRAL PIPELINE PROJECT (traveling nut) actuators are not permitted due to their inconsistent output torques through the 90 degree stroke. All manual direct buried service actuators shall be designed for a 300 foot-pound input torque against the closed and open travel stops. The owner reserves the right to field verify. M. Worm-Gear Actuators: All valves including submerged and buried valves, shall be equipped with top tier AWWA worm-gear actuators, lubricated and sealed to prevent entry of dirt or water into the housing. Buried service valves shall be 90% or greater, grease packed. Submerged service valves in potable water applications shall be 100% grease filled with FDA approved food grade grease. Documentation for the selected grease for submerged service valves shall accompany submittals. The owner reserves the right to field verify grease levels. Non-complying gears shall be remedied by the factory, verified by the customer and signed off by both parties. Gears are recommended to be Auma and are required to be of an equal or better quality. No name or unbranded actuators will not be accepted. N. Hardware: All fasteners and hardware shall be type 316 Stainless Steel. O. Paint and coatings: The manufacturer is required to have and follow a system of valve preparation and coating which assures a quality holiday free application and which maximizes the available multi-decade protection the coating offers. Manufacturers that do not properly prepare or coat their valves properly will not be accepted. The manufacturer must provide their written system of valve preparation and coating. This document shall include the methodologies used (quality compliance) as well as post application review (quality assurance). It will be based on a professional system of coating and grading such as NACE, SSPC, GSK, ISO or DIN and will include both text and color photo-documentation. The manufacturers coating system must be documented as well as implemented with a quality assurance program to prevent unacceptable deviation. This coating system shall be submitted for approval. It shall be titled, signed and dated by the manufacturers Coating Department Head, its’ Compliance Officer or an equal ranking staff.
1. Valves 48” and smaller: All external and internal surfaces except for the seating surface shall be 400 degree F plus, heat bonded fusion coated. Coating damaged in shipping or installation shall be noted and properly repaired to the satisfaction of the utility or its authorized agent. 2. Valve coating shall be white or blue. Red Oxide or any near color to rust shall not be acceptable. P. Manufacturers, or Equal 1. VAG Armaturen, EKN Double Offset
PART 3 -- EXECUTION
3.1 INSTALLATION
A. All exposed butterfly valves shall be installed in a manner whereby the complete valve can be removed without dismantling the valve or operator. The installation shall be in accordance with Section15200-Valves General.
BC&A BUTTERFLY VALVES JVWCD PAGE 15202-7 CENTRAL PIPELINE PROJECT B. Contractor shall use the provided lifting lugs to move all project valve(s). The use of chains, lifting straps, rope or any type other strapping through the valve body is strictly prohibited. Correct lifting procedures shall be the Contractor’s responsibility. As necessary, consultation with the valve manufacturer is recommended. The contractor shall be responsible for all damage and project delays resulting from improper lifting and moving procedures, these shall include but shall not be limited to: pulling the valve body out of round, gouges, scratches, displacing the gear box etc. C. Butterfly valves 54-inch and larger must be inspected and certified by the manufacturer that the final installation meets all the manufacturers requirements, and that the actuator and disk have not changed positions from that as successfully tested at the factory. D. Strict care shall be taken to assure valves are not installed under stress. In no instance shall adjacent mating flanges be forced into position. A progressive and proper star cross pattern shall be used to tighten valve flange mating bolts.
END OF SECTION
BC&A BUTTERFLY VALVES JVWCD PAGE 15202-8 CENTRAL PIPELINE PROJECT SECTION 15203 CHECK VALVES
PART 1 -- GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall provide check valves and appurtenances, complete and operable, in accordance with the Contract Documents.
B. The requirements of Section 15200 - Valves, General apply to this Section.
1.2 CONTRACTOR SUBMITTALS
A. Furnish submittals in accordance with Section 01300 – Contractor Submittals.
PART 2 -- PRODUCTS
2.1 PLASTIC BALL OR CHECK VALVES
A. General: Plastic ball check valves for corrosive fluids, in sizes up to 4-inches, shall be used for vertical up-flow conditions only, unless the valves are provided with spring actions.
B. Construction: The valve bodies and balls shall be of polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), polyvinylidene fluoride (PVDF), or polypropylene (PP) construction, as best suited for each individual service condition. They shall have unions with socket connections or flanged ends conforming to ASME B16.5 - Pipe Flanges and Flanged Fittings, class 150. Seals shall have Viton O-rings, and valve design shall minimize possibility of the balls sticking or chattering. The valves shall be suitable for a maximum working non-shock pressure of 150 psi at 73 degrees F.
C. Manufacturers, or Equal
1. ASAHI-AMERICA 2. George Fischer, Inc. 3. NIBCO Inc. (Chemtrol Division) 4. Spears Mfg. Co. (PVC, CPVC, AND PP only)
2.2 PLASTIC SWING OR WYE-CHECK VALVES
A. General: Plastic swing or wye-check valves for corrosive fluids, in sizes up to 8-inches or as available, may be used for horizontal or vertical up-flow conditions.
B. Construction: The valve bodies and discs or piston shall be of PVC, PP, or PVDF construction as best suited for each individual service condition. They shall have flanged ends conforming to ASME B16.5 Class 150, and flanged top access covers and shall shut positively at no-flow conditions. The seats and seals shall be of EPDM, Teflon, or Viton. The PVC valves shall be rated for a maximum non-shock working
BC&A CHECK VALVES JVWCD PAGE 15203-1 CENTRAL PIPLINE PROJECT pressure of 150 psi at 73 degrees F for sizes 3-inches and smaller. For larger sizes and other materials and temperatures the pressure rating may be lower.
C. Manufacturers, or Equal
1. ASAHI-AMERICA 2. George Fischer, Inc. 3. Spears Mfg. Co. (Plastic Swing Check only)
PART 3 -- EXECUTION
3.1 GENERAL
A. Valves shall be installed in accordance with provisions of Section 15200 - Valves, General.
END OF SECTION
BC&A CHECK VALVES JVWCD PAGE 15203-2 CENTRAL PIPLINE PROJECT SECTION 15204 BALL VALVES
PART 1 -- GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall provide ball valves and appurtenances, complete and operable, in accordance with the Contract Documents.
B. The requirements of Section 15200 - Valves, General apply to this Section.
C. The requirements of Section 15201 - Valve and Gate Actuators apply to this Section.
D. The requirements of Section 11258 - Chemical Feeding Equipment, General apply to this Section.
1.2 CONTRACTOR SUBMITTALS
A. Furnish submittals in accordance with Section 15200 - Valves, General, and 01300 – Contractor Submittals.
PART 2 -- PRODUCTS
2.1 METAL BALL VALVES (3-INCHES AND SMALLER)
A. General: Unless otherwise indicated, general purpose metal ball valves in sizes up to 4- inches shall have actuators in accordance with Section 15201 - Valve and Gate Actuators.
B. Body: Ball valves up to and including 1.5-inches in size shall have bronze or carbon steel 2 or 3 piece bodies with screwed ends for a pressure rating of not less than 600 psi WOG. Valves 2-inches to 3-inches in size shall have bronze or carbon steel 2 or 3 piece bodies with flanged ends for a pressure rating of ANSI 125 psi or 150 psi unless otherwise indicated.
C. Balls: The balls shall be solid chrome-plated brass or bronze, or stainless steel, with standard port (single reduction) or full port openings.
D. Stems: The valve stems shall be of the blow-out proof design, of bronze, stainless steel, or other acceptable construction, with reinforced teflon seal.
E. Seats: The valve seats shall be of teflon or Buna-N, for bi-directional service and easy replacement.
F. Manufacturers, or Equal
1. Conbraco Industries, Inc. (Apollo) 2. ITT Engineered Valves
BC&A BALL VALVES JVWCD PAGE 15204-1 CENTRAL PIPLINE PROJECT 3. Neles-Jamesbury, Inc. 4. Watts Regulator 5. Worcester Controls
2.2 PLASTIC BALL VALVES (1.5-inches and smaller)
A. General: Plastic ball valves for corrosive fluids shall be made of polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), or polyvinylidene fluoride (PVDF), as recommended by the manufacturer for the specific fluid application. Valves shall have manual actuators in accordance with Section 15201 - Valve and Gate Actuators, unless otherwise indicated.
B. Construction: Plastic ball valves shall have true-union ends or flanged ends to mate with ANSI B 16.5, class 150 flanges for easy removal. The balls shall have full size ports and teflon seats. Body seals, union O-ring seals, and stem seals shall be in accordance with the corrosion resistance requirements of [Section 11258]. External (without entering into the wetted area) seat packing adjustment is preferred. Metal reinforced stems to prevent accidental breakage are preferred. Ball valves for sodium hypochlorite solution service shall be drilled through the ball or body per valve manufacturer recommendation to relieve offgas and equalize pressure across the valve. The valves shall be suitable for a maximum working non-shock pressure of 150 psi at 73 degrees F for PVC and CPVC, with decreasing ratings for higher temperatures and other plastics.
C. Manufacturers, or Equal
1. ASAHI-America 2. George Fischer, Inc. 3. NIBCO Inc., (Chemtrol) 4. Plast-O-Matic Valves, Inc. 5. Spears Mfg. Co. 6. Watts Regulator
PART 3 -- EXECUTION
3.1 GENERAL
A. Valves shall be installed in accordance with Section 15200 – Valve, General. Care shall be taken that valves in plastic lines are well supported at each end of the valve.
END OF SECTION
BC&A BALL VALVES JVWCD PAGE 15204-2 CENTRAL PIPLINE PROJECT SECTION 15206 GATE VALVES
PART 1 -- GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall provide gate valves and appurtenances, complete and operable, in accordance with the Contract Documents.
B. The requirements of Section 15200 - Valves, General apply to this Section.
C. Shall conform to AWWA C509 Resilient-Seated Gate Valves for Water and Sewerage Systems.
1.2 CONTRACTOR SUBMITTALS
A. Furnish submittals in accordance with Section 15200.
PART 2 -- PRODUCTS
2.1 GENERAL
A. Buried valves shall be of the inside screw, non-rising stem type. The valve actuators shall be as indicated, with counter-clockwise opening stems, in accordance with Section 15201.
B. Gate valves 18-inches and larger shall be provided with a bypass line and isolation valve.
2.2 RESILIENT-SEATED GATE VALVES
A. General: Resilient-seated gate valves may be provided in lieu of metal-seated double- disc or solid-disc gate valves, at the discretion of the Engineer. B. Construction: Resilient-seated gate valves shall conform to AWWA C509 - Resilient- Seated Gate Valves for Water and Sewerage Systems. The valves shall be suitable for a minimum design working water pressure of 150 psig, with flanged, joint ends. The valve body, bonnet, and disc shall be of cast iron or ductile iron and the disc or body shall be rubber-coated. Body and bonnet wall thickness shall be equal to or greater than the minimum wall thickness as listed in Table 1 of AWWA C509. The stem, stem nuts, glands, and bushings shall be bronze, with the stem seal per AWWA C509.
C. Pressure Ratings:
1. AWWA C509 valves that are 3, 4, 6, 8, and 12 inches in size shall be rated for 200 psig minimum design working water pressure, and 16-, 20-, 24-, and 30-inch valves shall be rated for 150 psig minimum design working water pressure.
BC&A GATE VALVES JVWCD PAGE 15206-1 CENTRAL PIPLINE PROJECT 2. AWWA C515 valves 3- through 36-inch with outside screw-and-yoke (OS&Y) rising stem and 3- through 16-inch for non-rising-stem (NRS), shall be rated for 200 psig minimum design working water pressure.
D. Protective Coating: Valves shall be factory coated in accordance with Section 09800 - Protective Coating. The Contractor shall submit a test report from a coating inspector that the coating is holiday-free. The Contractor shall be aware that it may retain the services of a third party coating applicator to achieve the holiday-free requirement.
E. Actuators: Unless otherwise indicated, resilient-seated gate valves shall have manual actuators in accordance with Section 15201.
F. Manufacturers, or Equal
1. Mueller Company 2. M & H 3. Clow
2.3 HIGH-PRESSURE GATE VALVES (2- TO 12-INCHES)
A. Construction: High-pressure gate valves, except for buried valves, shall have cast iron bodies and flanged bonnets with outside screw & yoke rising stems conforming to ASTM A 126 - Gray Iron Castings for Valves, Flanges, and Pipe Fittings, with 250 psi flanged ends. The valves shall be rated for 250 psig steam and 500 psig cold water working pressure. The solid wedges shall be of bronze or cast iron, bronze-fitted, and the stem shall be of bronze with non-asbestos fiber packing.
B. Actuators: Unless otherwise indicated, high-pressure gate valves shall have cast iron or ductile iron handwheels with 2-inch square operating nuts, in accordance with Section 15201. C. Manufacturers, or Equal
1. Crane Company 2. Milwaukee Valve Company 3. Wm. Powell Company 4. Stockham Valves and Fittings 5. Walworth Company
PART 3 -- EXECUTION
3.1 GENERAL
A. Gate valves shall be installed in accordance with the provisions of Section 15200. Care shall be taken that valves in plastic lines are well supported at each end of the valve.
END OF SECTION
BC&A GATE VALVES JVWCD PAGE 15206-2 CENTRAL PIPLINE PROJECT SECTION 15207 PLUG VALVES
PART 1 -- GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall provide plug valves and appurtenances, complete and operable, in accordance with the Contract Documents.
B. The requirements of Section 15200 - Valves, General apply to this Section.
C. Plug valves shall have undergone a proof-of-design test to demonstrate that the valve components operate at the service flow, pressure, temperature, and fluid conditions, free from binding, excessive noise, and premature failures. Proof-of-design test results shall be available to the Engineer on request. The proof-of-design test shall be conducted in accordance with the applicable provisions of AWWA C517.
1.2 CONTRACTOR SUBMITTALS
A. Furnish submittals in accordance with Section 15200.
PART 2 -- PRODUCTS
2.1 ECCENTRIC PLUG VALVES (1/2-inch to 72-inches)
A. Construction: Eccentric plug valves shall be of the non-lubricated, eccentric plug design with cast iron bodies conforming to ASTM A 126 - Gray Iron Castings for Valves, Flanges, and Pipe Fittings, with ANSI 125 lb. flanged ends for valves 3-inches and larger, and screwed or flanged ends for smaller sizes. The plugs and shafts shall be of cast iron or ductile iron conforming to ASTM A 536 - Ductile Iron Castings, and the plugs shall be lined with a resilient coating, best suited for the specific service. The body shall be lined with a suitable elastomer, where required for a special service, or it shall be epoxy-lined in accordance with Section 09900 – Coatings and Painting. The seats shall be of nickel or stainless steel welded to the body. Top and bottom shaft bearings shall be of permanently lubricated stainless steel or Teflon coated stainless steel. Grit seals of Teflon, Nylatron, or similar suitable material shall be at the top and bottom plug journals. Valves up to and including 20-inches in size shall have an unobstructed port area of not less than 80 percent of full pipe area, and not less than 70 percent for larger valves. Eccentric plug valves shall have a pressure rating as required on the hydraulic test data sheet, for bubble-tight shut-off in the standard flow direction, and 25 psi WOG in the reverse flow direction. The stem seal shall consist of field adjustable packing, replaceable without removal of the actuator, or of self-adjusting U-cup packing.
B. Actuators: Unless otherwise indicated, eccentric plug valves 3-inches and smaller shall have operating levers; larger valves shall have worm-gear actuators. Valve actuators shall be in accordance with Section 15201.
BC&A PLUG VALVES JVWCD PAGE 15207-1 CENTRAL PIPLINE PROJECT C. Manufacturers, or Equal
1. DeZurik Corporation 2. Clow Valve Company 3. Val-Matic Valve
PART 3 -- EXECUTION
3.1 INSTALLATION
A. Plug valves shall be installed in strict accordance with the manufacturer's published recommendations and the applicable provisions of Section 15200.
B. Eccentric Plug Valves: Unless otherwise directed, the following rules shall be observed for the installation of eccentric plug valves on sewage, sludge, or other liquid systems containing solids, silt, or fine sand:
1. The valves shall be positioned with the stem in the horizontal direction. 2. In horizontal pipelines, the plug shall swing upwards when opening, to permit flushing out of solids. 3. The orientation of the valve shall prevent the valve body from filling up with solids when closed; however, where the pressure differential through the valve exceeds 25 psi, the higher pressure for valves without worm gear, electric, or air operators shall be through the valve to force the plug against the seat. 4. Valves, which may be closed for extended periods (stand-by, bypass, or drain lines) and valves with reversed flow (higher pressure on downstream side, forcing the plug away from its seat), shall be equipped with worm gear operators for the full range of sizes. 5. For special applications or when in doubt, consult with the manufacturer prior to installation.
END OF SECTION
BC&A PLUG VALVES JVWCD PAGE 15207-2 CENTRAL PIPLINE PROJECT SECTION 15215 PRESSURE REDUCING VALVES
PART 1 – GENERAL
1.1 THE REQUIREMENT
A. The CONTRACTOR shall provide pressure reducing valves and appurtenances, complete and operable, in accordance with the Contract Documents.
B. The requirements of Section 15200 - Valves, General, apply to this Section.
1.2 CONTRACTOR SUBMITTALS
A. The CONTRACTOR shall furnish submittals in accordance with Section 15200 – Valves, General and Section 01300 – Contractor Submittals, including a cavitation study from the valve manufacturer.
PART 2 – PRODUCTS
2.1 GENERAL
A. Function: Pressure reducing valves shall reduce a higher upstream pressure to a pre- set, lower, constant pressure, regardless of fluctuations in the upstream pressure.
B. Operation: The valves shall be hydraulically operated, with diaphragm or piston direct action, pilot-controlled, per paragraph 2.2, and shall be of the globe or angle pattern as indicated. All necessary repairs shall be possible without removing the valves from the pipeline. The smaller direct-acting valves with threaded ends per paragraph 2.3, shall be suitable for water or air service and shall be of the globe patterns.
2.2 FLANGED VALVES, SIZES 1 1/2 INCHES THROUGH 42 INCHES
A. Valve Body: The valve body shall be of cast iron to ASTM A 48 - Gray Iron Castings, or ASTM A 126 - Gray Iron Castings for Valves, Flanges, and Pipe Fittings, with 125 lb or 250 lb flanged ends to ANSI/ASME B 16.1 - Cast Iron Pipe Flanges and Flanged Fittings, Class 25, 125, 250, and 800, or the body shall be of ductile iron to ASTM A 536 - Ductile Iron Castings, with 150 lb or 300 lb flanged ends to ANSI/ASME B 16.42 - Ductile Iron Pipe Flanges and Flanged Fittings. The valve cover shall be flanged and be the same material as the body. Contractor is to select the appropriate valve pressure class as listed in the valve schedule and as recommended by the valve manufacturer to provide suitable operating service.
B. Valve Trim: The valve stems with position indication, springs, body seat rings, and all bolts, nuts, and washers shall be of Type 302, 303, or 316 stainless steel. The valve stems shall have top and bottom guides. All rubber parts shall be of Buna-N. The diaphragms shall be of Nylon-reinforced Buna-N, supported firmly between body and valve cover. The valve pistons and piston liners shall be bronze to ASTM B 62 - Composition Bronze or Ounce Metal Castings.
BC&A PRESSURE REDUCING VALVES JVWCD PAGE 15218-1 CENTRAL PIPLINE PROJECT C. Valve Controls: The valve shall be provided with a complete, externally mounted control system, including speed control needle valves, strainers, check valve, isolation valves, and all necessary copper or stainless steel connecting tubing and fittings. The controls shall be capable of achieving all the flow and speed adjustment indicated.
D. Factory Tests and Warranty: All valves shall be factory tested with a hydrostatic test and a functional test and a test certificate shall be submitted to the ENGINEER prior to delivery of the valve. The valve shall be warranted for a period of 3 years from the date of shipment to be free of defects in materials and workmanship
E. Spare Parts: The following spare parts shall be furnished in accordance with Section 15200: 1. One set of all resilient seals and discs 2. One diaphragm (for diaphragm valves, only)
F. Manufacturers, or equal 1. Cla-Val Company 2. GA Industries 3. OCV Control Valves 4. Ross Valve Mfg. Co., Inc. 5. Singer Valve, Inc. 6. Watts, ACV
2.3 THREADED VALVES, SIZES 1/2 TO 2-1/2 INCHES
A. Valve Body: The valve body shall be bronze to ASTM B 62 or cast steel, with a minimum pressure rating of 300 psi, and with threaded ends. The valve shall be provided with an integral or an attached strainer with access cap or plug and a flanged or threaded valve cover. The valve shall be actuated by a diaphragm or piston.
B. Valve Trim: The valve stems, springs, body seats, and washers shall be of Series 300 stainless steel. The strainers shall be of stainless steel or monel and the diaphragms shall be of reinforced neoprene. The valve pistons and piston liners shall be bronze to ASTM B 62.
C. Spare Parts: The following spare parts shall be furnished in accordance with Section 15200: 1. One set of all resilient seals and discs 2. One diaphragm (for diaphragm valves, only)
D. Manufacturers, or equal 1. Cla-Val Company 2. Fisher Controls 3. GA Industries 4. Watts, ACV 5. Wilkins Regulator Div. (Zurn Industries)
2.4 PLASTIC VALVES, SIZES 1/4 TO 3 INCHES
A. Plastic pressure reducing valves shall be designed for not less than 150 psi water working pressure and shall be suitable for the fluid service. For chemicals and all
BC&A PRESSURE REDUCING VALVES JVWCD PAGE 15218-2 CENTRAL PIPLINE PROJECT corrosive fluids, solenoid valves shall be PVC, CPVC, polypropylene (PP), polyvinylidene fluoride (PVDF), or teflon materials of construction as recommended by the manufacturer for the specific application.
B. Characteristics: Valves shall open when the outlet pressure drops below a set minimum value, and maintain the pressure and open wide as flow requirements dictate. Valves shall be spring or hydraulically operated, direct acting, adjustable, diaphragm or piston type as indicated.
C. Manufacturers, or equal 1. Corrosive Fluids 2. Plast-O-Matic Valves, Inc. 3. George Fisher
PART 3 – EXECUTION
3.1 INSTALLATION
A. Valves shall be installed in accordance with provisions of Section 15200 – Valves, General.
3.2 SERVICES OF MANUFACTURERS
A. Inspection, Startup, and Field Adjustment: The service representative of the valve manufacturer shall be present at the Site for two (2) work days, to assist the CONTRACTOR in the installation and adjustment of the valve(s).
B. Instruction of OWNERS Personnel: The training representative of the valve manufacturer shall be present at the Site for one (1) work day to instruct the personnel in the operation, adjustment, and maintenance of the valve(s).
C. For the purpose of this paragraph, a workday is defined as an eight hour period, excluding travel time.
- END OF SECTION -
BC&A PRESSURE REDUCING VALVES JVWCD PAGE 15218-3 CENTRAL PIPLINE PROJECT
SECTION 15218 PRESSURE RELIEF VALVES
PART 1 -- GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall provide pressure relief valves and appurtenances, complete and operable, in accordance with the Contract Documents.
B. The requirements of Section 15200 - Valves, General, apply to this Section.
1.2 CONTRACTOR SUBMITTALS
A. Furnish submittals in accordance with Section 15200.
1.3 SPECIAL WARRANTY REQUIREMENT
A. The valve shall be warranted for a period of 3 years from the date of shipment to be free of defects in materials and workmanship.
PART 2 -- PRODUCTS
2.1 FLANGED PRESSURE RELIEF VALVES, SIZES 1-1/2 INCHES THROUGH 42 INCHES
A. Valve Characteristics: The pressure relief valve shall open when the inlet pressure exceeds a set maximum level. It shall maintain that level and gradually close as the inlet pressure drops below the maximum pressure. The valve shall be a hydraulically operated, adjustable, pilot controlled, diaphragm, or piston type glove or angle valve as indicated. All necessary repairs shall be possible without removing the valve from the pipeline.
B. Valve Body: The valve body shall be of cast iron, ASTM A 48 - Gray Iron Castings, or ASTM A 126 - Gray Iron Castings for Valves, Flanges, and Pipe Fittings, with 125 lb or 250 lb flanged ends to ANSI/ASME B 16.1 - Cast Iron Pipe Flanges and Flanged Fittings, Class 25, 125, 250, and 800, or the body shall be of ductile iron to ASTM A 536 - Ductile Iron Castings, with 150 lb or 300 lb flanged ends to ANSI/ASME B 16.42 - Ductile Iron Pipe Flanges and Flanged Fittings. The valve cover shall be flanged and be of the same material as the body. Contractor is to select the appropriate valve pressure class as listed in the valve schedule and as recommended by the valve manufacturer to provide suitable operating service.
C. Valve Trim: The valve stems, springs, body seat rings, and all bolts, nuts, and washers shall be of Type 302, 303, or 316 stainless steel. The valve stems shall have top and bottom guides. All rubber parts shall be of Buna-N. The diaphragms shall be of Nylon- reinforced Buna-N, supported firmly between body and valve cover. The valve pistons and piston liners shall be bronze to ASTM B 62 - Composition Bronze or Ounce Metal Castings.
BC&A PRESSURE RELIEF VALVES JVWCD PAGE 15218-1 CENTRAL PIPLINE PROJECT D. Valve Controls: The valve shall be furnished with a complete, externally mounted control system, including adjustable speed control needle valves, strainer, and all necessary copper or stainless steel connecting tubing and fittings. The controls shall be capable of achieving all the flow and speed adjustment indicated.
E. Factory Tests and Warranty: Valves shall be factory tested with a hydrostatic test and a functional test and a test certificate shall be submitted to the ENGINEER prior to delivery of valves. Valves shall be warranted for a period of 3 years from the date of shipment to be free of defects in materials and workmanship.
F. Operating Conditions: The 12-inch pressure relief valves in the Mainline Valve and Blowoff Vault shall be designed to operate under the following conditions: 1. Total flow from pump station [gpm/cfs] - 15,710/35 2. Maximum inlet pressure (psi) - 240 3. Number of Valves - 2 4. Valve size (inches) - 12 5. Size of pipeline (inches diameter) - 12 6. Valves shall be set in the factory to open at and limit inlet pressure to no more than 115 psi. 7. Outlet pressure (psi) - 0-5
G. Spare Parts: The following spare parts shall be furnished in accordance with Section 15200: 1. 1 set of all resilient seals, and discs 2. 1 diaphragm (for diaphragm valves, only)
H. Manufacturers, or equal 1. Cla-Val Company 2. Golden-Anderson 3. OCV Control Valves 4. Ross Valve Mfg. Co., Inc. 5. Singer Valve, Inc. 6. Watts, ACV
PART 3 -- EXECUTION
3.1 INSTALLATION
A. Valves shall be installed in accordance with provisions of Section 15200.
3.2 SERVICES OF MANUFACTURER
A. Inspection, Startup, and Field Adjustment: The service representative of the valve manufacturer shall be present at the Site for two (2) work days, to assist the CONTRACTOR in the installation and adjustment of the valve(s).
B. Instruction of OWNERS Personnel: The training representative of the valve manufacturer shall be present at the Site for one (1) work day to instruct the personnel in the operation, adjustment, and maintenance of the valve(s).
BC&A PRESSURE RELIEF VALVES JVWCD PAGE 15218-2 CENTRAL PIPLINE PROJECT C. For the purpose of this paragraph, a work day is defined as an eight hour period, excluding travel time.
END OF SECTION
BC&A PRESSURE RELIEF VALVES JVWCD PAGE 15218-3 CENTRAL PIPLINE PROJECT
SECTION 15235 FIRE HYDRANTS
PART 1 -- GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall provide fire hydrants and appurtenances, complete and operable, in accordance with the Contract Documents.
B. This Section covers the dry-barrel and the wet-barrel types of fire hydrant: however, unless otherwise indicated, the dry-barrel hydrant shall be provided.
PART 2 -- PRODUCTS
2.1 DRY-BARREL FIRE HYDRANTS
A. Construction: Unless otherwise indicated, hydrants shall be the dry-barrel type according to AWWA C502, with a minimum of one 4-inch or 4-1/2 inch steamer connection, one 2-1/2 inch hose connection, and a 6-inch diameter inlet, except as shown otherwise on the Contract Drawings. The hose and steamer connections shall be provided with cast iron caps and metal chains. The barrel shall have a cast iron breakaway section above ground and a lower barrel of ductile iron, with an elbow or tee- section at the base. The stem shall have a breakaway coupling, or there shall be some other safety device in case of a fracture. Each hydrant shall be isolated by an individual buried gate valve with cast iron box and cover. Bolts, nuts, and washers shall be Type 316 stainless steel, except where otherwise required for structural reasons.
B. Working Pressures: Normal working pressure on the hydrants will be as shown on the hydraulic data sheet.
C. Test Pressures: The hydrants shall be designed and constructed for a suitable working pressure of 150 psig. Interior and exterior surfaces shall be coated in accordance with AWWA C 550 and Section 09900 – Coatings and Painting.
D. Manufacturers, or Equal
1. American Flow Control (Darling) 2. American Valve and Hydrant 3. Dresser (M & H Valve Co.) 4. East Jordan Iron Works, Inc.
PART 3 -- EXECUTION
3.1 INSTALLATION
A. Fire hydrants shall be installed in strict accordance with the manufacturer's published recommendations, AWWA standards, applicable codes, and the applicable provisions of Section 15200 - Valves, General. Installations shall be to the satisfaction of the local Salt Lake County Fire and Building department.
BC&A FIRE HYDRANTS JVWCD PAGE 15235-1 CENTRAL PIPLINE PROJECT
B. Hydrants with other than flanged inlets shall be installed with a concrete thrust block, calculated for two times the maximum expected water pressure. Dry-barrel fire hydrants shall be set on a bed of pea gravel not less than 24-inches deep and 3-feet square for drainage or as required by local regulations and conditions.
END OF SECTION
BC&A FIRE HYDRANTS JVWCD PAGE 15235-2 CENTRAL PIPLINE PROJECT SECTION 15420 EMERGENCY EYE/FACE WASH AND SHOWER EQUIPMENT
PART 1 – GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section includes the following emergency plumbing fixtures:
1. Eye/face wash equipment. 2. Combination units. 3. Water-tempering equipment
1.3 DEFINITIONS
A. Accessible Fixture: Emergency plumbing fixture that can be approached, entered, and used by people with disabilities.
B. Cooled Water: Cooled potable water produced by water cooler.
C. Plumbed Emergency Plumbing Fixture: Fixture with fixed, potable-water supply.
D. PVC: Polyvinyl chloride plastic.
E. Self-Contained Emergency Plumbing Fixture: Fixture with flushing-fluid-solution supply.
F. Tepid: Approximately 85 deg F temperature.
1. Allowable Variation: Plus or minus 5 deg F.
1.5 QUALITY ASSURANCE
A. ANSI Standard: Comply with ANSI Z358.1, "Emergency Eyewash and Shower Equipment.”
B. Regulatory Requirements: Comply with requirements in ICC A117.1, "Accessible and Usable Buildings and Facilities"; about plumbing fixtures for people with disabilities.
1.3 REFERENCES
A. American National Standards Institute (ANSI):
Z358.1 Emergency Eyewash and Shower Equipment Z535.1 Safety Color Code
BC&A EMERGENCY EYE/FACE WASH JVWCD AND SHOWER EQUIPMENT CENTRAL PIPLINE PROJECT PAGE 15420-1
B. NIOSH Schedule 13F.
1.3 SUBMITTALS
A. Submit shop drawings in accordance with Section 01300 – Contractor Submittals.
B. Product Data: 1. Submit manufacturer’s product literature information for products specified. 2. Manufacturer’s Installation Instructions.
A. Product Data: Include flow rates and capacities; shipping, installed, and operating weights; furnished specialties; and accessories for each product indicated.
C. Operation and Maintenance Data.
D. Operating and Maintenance Information for Safety Detectors and Breathing Apparatus; 6 complete sets.
E. Warranty.
1.4 QUALITY ASSURANCE
A. Manufacturer Qualifications: Show evidence that the firm has been engaged in producing such materials and products for at least 5 years and that the product submitted has a satisfactory performance record of at least 5 years.
B. Installer Qualifications; Installer shall have 3 years experience in installing these materials for similar projects and shall be approved by the manufacturer prior to bidding of the project.
C. Regulatory Requirements:
1. As applicable, equipment of this Section shall comply with requirements of public agencies of the State of Utah including OSHA, Underwriters Laboratories, NFPA, and ASME.
1.5 DELIVERY, STORAGE, AND HANDLING
A. Packing and Shipping: Deliver to the job site in manufacturer’s original containers.
B. Delivery: After wet operations in building are completed.
C. Storage and Protection: Store materials in original, unopened containers in compliance with manufacturer’s printed instructions.
D. Keep materials dry until ready for use. Keep packages of material off the ground, under cover, and away from sweating walls and other damp surfaces.
BC&A EMERGENCY EYE/FACE WASH JVWCD AND SHOWER EQUIPMENT CENTRAL PIPLINE PROJECT PAGE 15420-2 E. Protect finished surfaces from soiling and damage during handling and installation. Keep covered with a protective covering.
PART 2 – PRODUCTS
2.2 EYE/FACE WASH EQUIPMENT
A. Eye/Face Wash Equipment: Plumbed, adjacent-to-sink, swivel, counter-mounting type. 1. Available Manufacturers. 2. Manufacturers. a. Bradley Corporation. b. Encon Safety Products. c. Guardian Equipment Co. d. Acorn Safety. e. Haws Corporation. f. Lab Safety Supply, Inc. g. Speakman Co.
3. Capacity: Deliver potable water at rate not less than 3.0 gpm for at least 15 minutes. 4. Supply Piping: NPS 1/2 chrome-plated brass or stainless steel with flow regulator and stay-open control valve. 5. Control-Valve Actuator: Paddle. 6. Omit receptor and drain.
2.3 COMBINATION UNITS
A. Combination Units: Plumbed, accessible, freestanding type with emergency shower and eye/face wash equipment. 1. Available Manufacturers. a. Bradley Corporation. b. Encon Safety Products. c. Guardian Equipment Co. d. Acorn Safety. e. Haws Corporation. f. Lab Safety Supply, Inc. g. Speakman Co. 3. Piping: Stainless steel. a. Unit Supply: NPS 1-1/4 minimum from top. b. Unit Drain: Outlet at side near bottom. c. Shower Supply: NPS 1 with flow regulator and stay-open control valve. d. Eye/Face Wash Supply: NPS 1/2 with flow regulator and stay-open control valve.
4. Shower Capacity: Deliver potable water at rate not less than 20 gpm for at least 15 minutes. a. Control-Valve Actuator: Pull rod. b. Shower Head: 8 inch minimum diameter, stainless steel.
BC&A EMERGENCY EYE/FACE WASH JVWCD AND SHOWER EQUIPMENT CENTRAL PIPLINE PROJECT PAGE 15420-3 5. Eye/Face Wash Equipment: With capacity to deliver potable water at rate not less than 3.0 gpm for at least 15 minutes. a. Control-Valve Actuator: Paddle. b. Receptor: Stainless-steel bowl.
2.4 WATER-TEMPERING EQUIPMENT
A. Hot and Cold-Water-Tempering Equipment,: Factory-fabricated equipment including water thermostatic mixing valve designed to provide 85 deg F potable water at emergency plumbing fixtures, to maintain temperature at plus or minus 5 deg F throughout required 15-minute test period, and in case of unit failure to continue cold- water flow, with union connections, controls, corrosion-resistant metal piping, and enclosure.
1. Available Manufacturers. a. Bradley Corporation. b. Encon Safety Products. c. Guardian Equipment Co. d. Acorn Safety. e. Haws Corporation. f. Lab Safety Supply, Inc. g. Speakman Co.
PART 3 – EXECUTION
3.1 INSTALLATION
A. Install products in accordance with manufacturers’ recommendations.
B. Install fixed equipment in accordance with manufacturer’s instructions.
C. Plumbing work shall be in accordance with Section 15052 – Common Results for Plumbing.
D. Electrical connections and distribution shall be in accordance with Section 16050 – General Provisions.
3.2 PROTECTION
A. Repair or replace defective equipment with new.
END OF SECTION
BC&A EMERGENCY EYE/FACE WASH JVWCD AND SHOWER EQUIPMENT CENTRAL PIPLINE PROJECT PAGE 15420-4 SECTION 15485 ELECTRIC WATER HEATERS
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section includes the following electric water heaters: 1. Commercial, storage electric water heaters. 2. Compression tanks. 3. Water heater accessories.
1.3 CONTRACTOR SUBMITTALS
A. Product Data: For each type and size of water heater indicated. Include rated capacities, operating characteristics, furnished specialties, and accessories.
B. Field quality-control test reports.
C. Operation and Maintenance Data: For electric water heaters to include in emergency, operation, and maintenance manuals.
D. LEED Submittal:
1. Product Data for Prerequisite EA 2: Documentation indicating that units comply with ASHRAE/IESNA 90.1-2004, Section 7 – Service Water Heating.
1.4 QUALITY ASSURANCE
A. Source Limitations: Obtain same type of electric water heaters through one source from a single manufacturer.
B. Product Options: Drawings indicate size, profiles, and dimensional requirements of electric water heaters and are based on the specific system indicated. Refer to Division 1 Section "Product Requirements."
C. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use.
D. ASME Compliance: Where indicated, fabricate and label commercial water heater storage tanks to comply with ASME Boiler and Pressure Vessel Code: Section VIII, Division 1.
BC&A ELECTRIC WATER HEATERS JVWCD PAGE 15485-1 CENTRAL PIPLINE PROJECT E. Comply with NSF 61, "Drinking Water System Components - Health Effects; Sections 1 through 9," for all components that will be in contact with potable water.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. In other Part 2 articles where titles below introduce lists, the following requirements apply to product selection:
1. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, manufacturers specified.
2.2 COMMERCIAL ELECTRIC WATER HEATERS
A. Commercial, Storage Electric Water Heaters: Comply with UL 1453 requirements for storage-tank-type water heaters.
1. Available Manufacturers: a. Bradford White Corporation. b. Lochinvar Corporation. c. PVI Industries, LLC. d. Rheem Water Heater Div.; Rheem Manufacturing Company. e. Ruud Water Heater Div.; Rheem Manufacturing Company. f. Smith, A. O. Water Products Company. g. State Industries, Inc. 2. Storage-Tank Construction: ASME-code, steel vertical arrangement. a. Tappings: Factory fabricated of materials compatible with tank and piping connections. Attach tappings to tank before testing. 1) NPS 2 and Smaller: Threaded ends according to ASME B1.20.1. 2) NPS 2-1/2 and Larger: Flanged ends according to ASME B16.5 for steel and stainless-steel flanges, and according to ASME B16.24 for copper and copper-alloy flanges. b. Pressure Rating: 150 psig. c. Interior Finish: Comply with NSF 61 barrier materials for potable-water tank linings, including extending lining material into tappings. 3. Factory-Installed Storage-Tank Appurtenances: a. Anode Rod: Replaceable magnesium. b. Drain Valve: Corrosion-resistant metal complying with ASSE 1005. c. Insulation: Comply with ASHRAE/IESNA 90.1. d. Jacket: Steel with enameled finish. e. Heating Elements: Electric, screw-in or bolt-on immersion type arranged in multiples of three. f. Temperature Control: Adjustable thermostat. g. Safety Controls: High-temperature-limit and low-water cutoff devices or systems. h. Relief Valves: ASME rated and stamped and complying with ASME PTC 25.3, for combination temperature and pressure relief valves. Include one or more relief valves with total relieving capacity at least as
BC&A ELECTRIC WATER HEATERS JVWCD PAGE 15485-2 CENTRAL PIPLINE PROJECT great as heat input, and include pressure setting less than water heater working-pressure rating. Select one relief valve with sensing element that extends into storage tank.
2.3 COMPRESSION TANKS
A. Description: Steel pressure-rated tank constructed with welded joints and factory- installed butyl-rubber diaphragm. Include air precharge to minimum system-operating pressure at tank.
1. Available Manufacturers: a. AMTROL Inc. b. Armstrong Pumps, Inc. c. Flexcon Industries. d. Smith, A. O.; Aqua-Air Div. e. State Industries, Inc. f. Taco, Inc. g. Watts Regulator Co. 2. Construction: a. Tappings: Factory-fabricated steel, welded to tank before testing and labeling. Include ASME B1.20.1, pipe thread. b. Interior Finish: Comply with NSF 61 barrier materials for potable-water tank linings, including extending finish into and through tank fittings and outlets. c. Air-Charging Valve: Factory installed.
2.4 WATER HEATER ACCESSORIES
A. Combination Temperature and Pressure Relief Valves: ASME rated and stamped and complying with ASME PTC 25.3. Include relieving capacity at least as great as heat input, and include pressure setting less than water heater working-pressure rating. Select relief valves with sensing element that extends into storage tank.
B. Pressure Relief Valves: ASME rated and stamped and complying with ASME PTC 25.3. Include pressure setting less than water heater working-pressure rating.
C. Water Heater Stand and Drain-Pan Units: High-density-polyethylene-plastic, 18-inch- high, enclosed-base stand complying with IAPMO PS 103 and IAS No. 2. Include integral or separate drain pan with raised edge and NPS 1 drain outlet with ASME B1.20.1 pipe thread.
D. Water Heater Mounting Brackets: Water heater manufacturer's factory-fabricated steel bracket for wall mounting and capable of supporting water heater and water.
E. Drain Pans: Corrosion-resistant metal with raised edge. Include dimensions not less than base of water heater and include drain outlet not less than NPS 3/4.
BC&A ELECTRIC WATER HEATERS JVWCD PAGE 15485-3 CENTRAL PIPLINE PROJECT F. Piping-Type Heat Traps: Field-fabricated piping arrangement according to ASHRAE/IESNA 90.1 or ASHRAE 90.2.
G. Shock Absorbers: ASSE 1010 or PDI WH 201, Size A water hammer arrester.
PART 3 - EXECUTION
3.1 WATER HEATER INSTALLATION
A. Install commercial water heaters on concrete bases per structural details.
B. Install water heaters level and plumb, according to layout drawings, original design, and referenced standards. Maintain manufacturer's recommended clearances. Arrange units so controls and devices needing service are accessible.
C. Install combination temperature and pressure relief valves in top portion of storage tanks. Use relief valves with sensing elements that extend into tanks. Extend commercial-water-heater relief-valve outlet, with drain piping same as domestic water piping in continuous downward pitch, and discharge by positive air gap onto closest floor drain.
D. Install water-heater drain piping as indirect waste to spill by positive air gap into open drains or over floor drains. Install hose-end drain valves at low points in water piping for water heaters that do not have tank drains.
E. Install thermometer on outlet piping of water heaters.
F. Fill water heaters with water.
G. Charge compression tanks with air.
3.2 CONNECTIONS
A. Piping installation requirements are specified in other Division 15 Sections. Drawings indicate general arrangement of piping, fittings, and specialties.
B. Install piping adjacent to water heaters to allow service and maintenance. Arrange piping for easy removal of water heaters.
C. Ground equipment according to Section 16060 - Grounding and Bonding.
D. Connect wiring according to Section 16150 – Wiring Connections.
3.3 FIELD QUALITY CONTROL
A. Perform the following field tests and inspections and prepare test reports:
1. Leak Test: After installation, test for leaks. Repair leaks and retest until no leaks exist. 2. Operational Test: After electrical circuitry has been energized, confirm proper operation.
BC&A ELECTRIC WATER HEATERS JVWCD PAGE 15485-4 CENTRAL PIPLINE PROJECT 3. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment.
B. Remove and replace water heaters that do not pass tests and inspections and retest as specified above.
END OF SECTION
BC&A ELECTRIC WATER HEATERS JVWCD PAGE 15485-5 CENTRAL PIPLINE PROJECT
SECTION 15543 FUEL-FIRED UNIT HEATERS
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section includes gas fired unit heaters.
1.3 SUBMITTALS
A. Product Data: Include rated capacities; wiring diagrams; operation and maintenance data; shipping, installed, and operating weights; furnished specialties; and accessories.
1.4 QUALITY ASSURANCE
A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. In other Part 2 articles where subparagraph titles below introduce lists, the following requirements apply for product selection:
1. SELECT ONLY ONE OF THE FOLLOWING.Manufacturers: Subject to compliance with requirements, provide products by the manufacturers specified.
2.2 GAS-FIRED UNIT HEATERS
A. Manufacturers:
1. Lennox Industries, Inc. 2. Modine Mfg. Co. 3. Reznor/Thomas & Betts. 4. Sterling Gas-Fired Heating Equipment Div.
B. Description: Factory assembled, piped, and wired, and complying with AGA Z83.8, "Gas Unit Heaters."
1. AGA Approval: Designed and certified by and bearing label of American Gas Association. 2. Type of Gas: Designed and built to burn natural gas with characteristics same as those of gas available at Project site.
CTA ARCHITECTS ENGINEERS FUEL-FIRED UNIT HEATERS JVWCD PAGE 15543 - 1 CENTRAL PIPELINE PROJECT
C. Venting: Separated.
D. Housing: Steel, with integral draft hood and inserts for suspension mounting rods.
1. External Casings and Cabinets: Powder coating over corrosion-resistant-treated surface.
E. Heat Exchanger: Aluminized steel.
F. Burners: Aluminized steel with stainless-steel inserts.
1. High-Altitude Kit: For Project elevation above sea level.
G. Unit Fan: Propeller fan with aluminum blades dynamically balanced and resiliently mounted.
1. Steel fan-blade guard. 2. Motors: Totally enclosed with internal thermal-overload protection.
H. Controls: Regulated redundant 24 V ac gas valve containing pilot solenoid valve, electric gas valve, pilot filter, pressure regulator, pilot shutoff, and manual shutoff all in one body.
1. Gas Control Valve: Single stage. 2. Ignition: Electronically controlled electric spark with flame sensor. 3. Fan Thermal Switch: Operates fan on heat-exchanger temperature. 4. Vent Flow Verification: Flame rollout switch. 5. Control Transformer: 24 V ac. 6. High Limit: Thermal switch or fuse to stop burner. 7. Thermostat: Thermostats shall be furnished with Unit Heater GUH-1.
I. Discharge Louvers: Independently adjustable horizontal blades.
J. Accessories:
1. Four-point suspension kit. 2. Concentric, Terminal Vent Assembly: Combined combustion-air inlet and power- vent outlet. Include adapter assembly for connection to inlet and outlet pipes, and flashing for wall penetration.
2.3 FACTORY FINISHES
A. Finish: Manufacturer's standard paint applied to factory-assembled and -tested, fuel- fired unit heater before shipping.
PART 3 - EXECUTION
3.1 EXAMINATION
A. Examine roughing-in for unit heater piping systems to verify actual locations of piping connections before equipment installation.
CTA ARCHITECTS ENGINEERS FUEL-FIRED UNIT HEATERS JVWCD PAGE 15543 - 2 CENTRAL PIPELINE PROJECT
B. Proceed with installation only after unsatisfactory conditions have been corrected.
3.2 INSTALLATION
A. Install unit heaters level and plumb.
B. Install and connect gas-fired unit heaters and associated fuel and vent features and systems according to NFPA 54, applicable local codes and regulations, and manufacturer's written installation instructions.
C. Suspended Units: Suspend from substrate using threaded rods, spring hangers, and building attachments. Secure rods to unit hanger attachments. Adjust hangers so unit is level and plumb.
1. Restrain the unit to resist code-required horizontal acceleration.
3.3 CONNECTIONS
A. Piping installation requirements are specified in other Division 15 Sections. Drawings indicate general arrangement of piping, fittings, and specialties.
B. Install piping adjacent to machine to allow service and maintenance.
C. Gas Piping: Comply with applicable requirements in Division 15 Section "Natural Gas Piping." Connect gas piping to gas train inlet; provide union with enough clearance for burner removal and service. Provide AGA-approved flexible units.
D. Electrical: Comply with applicable requirements in Division 16 Sections.
1. Install electrical devices furnished with heaters but not specified to be factory mounted.
E. Ground equipment according to Division 16 Section "Grounding and Bonding."
F. Tighten electrical connectors and terminals according to manufacturer's published torque-tightening values. If manufacturer's torque values are not indicated, use those specified in UL 486A and UL 486B.
3.4 FIELD QUALITY CONTROL
A. Manufacturer's Field Service: Engage a factory-authorized service representative to inspect field-assembled components and equipment installation, including piping and electrical connections.
1. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment. 2. Verify bearing lubrication. 3. Verify proper motor rotation.
CTA ARCHITECTS ENGINEERS FUEL-FIRED UNIT HEATERS JVWCD PAGE 15543 - 3 CENTRAL PIPELINE PROJECT
3.5 ADJUSTING
A. Adjust initial temperature set points.
B. Adjust burner and other unit components for optimum heating performance and efficiency.
3.6 DEMONSTRATION
A. Engage a factory-authorized service representative to train Owner's maintenance personnel to adjust, operate, and maintain fuel-fired unit heaters.
END OF SECTION
CTA ARCHITECTS ENGINEERS FUEL-FIRED UNIT HEATERS JVWCD PAGE 15543 - 4 CENTRAL PIPELINE PROJECT
SECTION 15785 AIR-TO-AIR ENERGY RECOVERY EQUIPMENT
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section.
1.2 SUMMARY
A. Section Includes:
1. Custom Fixed Plate Type Heat Recovery Units.
1.3 SUBMITTALS
A. Product Data: For each type of product indicated. Include rated capacities, furnished specialties, and accessories.
B. Shop Drawings: For air-to-air energy recovery equipment. Include plans, elevations, sections, details, and attachments to other work.
1. Detail equipment assemblies and indicate dimensions, weights, loads, required clearances, method of field assembly, components, and location and size of each field connection. 2. Wiring Diagrams: For power, signal, and control wiring.
C. Field quality-control reports.
D. Operation and Maintenance Data: For air-to-air energy recovery equipment to include in maintenance manuals.
1.4 QUALITY ASSURANCE
A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application.
B. ARI Compliance: Capacity ratings for air-to-air energy recovery equipment shall comply with ARI 1060, "Rating Air-to-Air Energy Recovery Equipment."
C. ASHRAE Compliance: Capacity ratings for air-to-air energy recovery equipment shall comply with ASHRAE 84, "Method of Testing Air-to-Air Heat Exchangers."
D. UL Compliance: Packaged heat recovery ventilators shall comply with requirements in UL 1812, "Ducted Heat Recovery Ventilators"; or UL 1815, "Nonducted Heat Recovery Ventilators."
CTA ARCHITECTS ENGINEERS AIR-TO-AIR ENERGY RECOVERY EQUIPMENT JVWCD PAGE 15785 - 1 CENTRAL PIPELINE PROJECT 1.5 COORDINATION
A. Coordinate layout and installation of air-to-air energy recovery equipment and suspension system with other construction that penetrates ceilings or is supported by them, including light fixtures, HVAC equipment, fire-suppression system, and partition assemblies.
B. Coordinate sizes and locations of concrete bases with actual equipment provided.
C. Coordinate sizes and locations of roof curbs, equipment supports, and roof penetrations with actual equipment provided.
PART 2 - PRODUCTS
2.1 CUSTOM FIXED PLATE TYPE HEAT RECOVERY UNITS
A. Manufacturers: Subject to compliance with requirements, provide products by one of the following:
1. Des Champs Technologies. 2. Engineered Air. 3. Governaire. 4. I.C.E. Industrial Commercial Equipment. 5. Innovent Air Handling Equipment. 6. Munters. 7. Racan Carrier. 8. Reznor. 9. Venmar CES, Inc.
B. Unit Construction: White, baked on, polyester pre-painted galvanized steel package. Cabinet shall be insulated throughout with a minimum 1 inch foil faced fire retardant material. Main access panel shall be hinged and provide access to all components.
C. Heat Recovery Device: Flat-plate heat exchanger, cross flow, made of polypropylene with a minimum 0.008 inch wall thickness and rated to UL94HB. Plate corners shall be sealed with silicone or hot melt and be capable of withstanding 10 inches of water pressure differentials without permanent deformation or decrease in performance. Heat exchanger shall operate at temperature up to 140 deg F. Energy transfer ratings shall be AHRI certified to AHRI standard 1060 and bear the AHRI Certified mark signature for the air-to-air energy recovery ventilation equipment program. Ratings "In accordance with 1060" without certification shall be deemed unacceptable. The flat plate heat exchanger shall be manufactured under ISO 9001-2000 certified quality procedures.
D. Blowers:
1. Fan ratings are based on tests made in accordance with AMCA Standard 210. 2. Blowers must be selected to operate on a stable, efficient part of the fan curve when delivering air quantities scheduled against static of the system. 3. Fan blades shall be statically and dynamically balanced and tested prior to shipment.
CTA ARCHITECTS ENGINEERS AIR-TO-AIR ENERGY RECOVERY EQUIPMENT JVWCD PAGE 15785 - 2 CENTRAL PIPELINE PROJECT 4. Fan shall be provided with internal vibration isolation mounts.
E. Heat Recovery Device: Flat-plate heat exchanger.
F. Filters: Unit shall include MEF supply filtration.
G. Piping and Wiring: Fabricate units with space within housing for piping and electrical conduits. Wire motors and controls so only external connections are required during installation.
H. Controls: Unit shall be provided with factory mounted and wired microprocessor control. All service connectors shall be quick disconnect type. Exhaust only defrost cycle to prevent frost from forming on the flat plate heat exchanger and to maintain exhaust ventilation at all times.
PART 3 - EXECUTION
3.1 EXAMINATION
A. Examine areas and conditions, with Installer present, for compliance with requirements for installation tolerances and other conditions affecting performance of the Work.
B. Examine casing insulation materials and filter media before air-to-air energy recovery equipment installation. Reject insulation materials and filter media that are wet, moisture damaged, or mold damaged.
C. Examine roughing-in for electrical services to verify actual locations of connections before installation.
D. Proceed with installation only after unsatisfactory conditions have been corrected.
3.2 INSTALLATION
A. Install fixed-plate heat exchangers so supply and exhaust airstreams flow in opposite directions.
B. Install on concrete base, level and secure. Secure air-to-air energy recovery equipment to concrete base with anchor bolts.
C. Unit Support: Install unit level on concrete base. Coordinate wall penetrations and flashing with wall construction. Secure air-to-air energy recovery equipment to structural support with anchor bolts.
D. Install and seismic restraints according to manufacturers' written instructions.
E. Install units with clearances for service and maintenance.
F. Install new filters at completion of equipment installation and before testing, adjusting, and balancing.
CTA ARCHITECTS ENGINEERS AIR-TO-AIR ENERGY RECOVERY EQUIPMENT JVWCD PAGE 15785 - 3 CENTRAL PIPELINE PROJECT G. Pipe drains from units and drain pans to nearest floor drain; use ASTM D 1785, Schedule 40 PVC pipe and solvent-welded fittings, same size as condensate drain connection.
H. Install unit per manufacturer's written installation instructions.
3.3 CONNECTIONS
A. Comply with requirements for ductwork specified in Division 15 Section "Metal Ducts."
B. Install piping adjacent to machine to allow service and maintenance.
3.4 FIELD QUALITY CONTROL
A. Manufacturer's Field Service: Engage a factory-authorized service representative to inspect, test, and adjust components, assemblies, and equipment installations, including connections.
B. Perform tests and inspections.
1. Manufacturer's Field Service: Engage a factory-authorized service representative to inspect components, assemblies, and equipment installations, including connections, and to assist in testing.
C. Tests and Inspections:
1. Operational Test: After electrical circuitry has been energized, start units to confirm proper motor rotation and unit operation. 2. Adjust seals and purge. 3. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment. 4. Set initial temperature and humidity set points. 5. Set field-adjustable switches and circuit-breaker trip ranges as indicated.
D. Air-to-air energy recovery equipment will be considered defective if it does not pass tests and inspections.
E. Prepare test and inspection reports.
3.5 DEMONSTRATION
A. Engage a factory-authorized service representative to train Owner's maintenance personnel to adjust, operate, and maintain air-to-air energy recovery units.
END OF SECTION
CTA ARCHITECTS ENGINEERS AIR-TO-AIR ENERGY RECOVERY EQUIPMENT JVWCD PAGE 15785 - 4 CENTRAL PIPELINE PROJECT SECTION 15815 METAL DUCTS
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section.
1.2 SUMMARY
A. Section Includes: 1. Rectangular ducts and fittings. 2. Single-wall round ducts and fittings.
1.3 WORK INCLUDED
A. Provide an installed duct system which will supply the air quantities indicated by the Drawings and have the lowest possible friction loss with the least possible leakage loss. Friction losses shall be minimized by reduction in the number of offsets and elbows by pre-planning the duct system installation and coordination with other trades to prevent interferences. Maintain access to accessories requiring maintenance, service, and inspection. Radius elbows are preferred for turns to minimize friction, noise, and vibrations, and especially for sections having large volume or higher velocities and sections which may have turbulence.
B. Provide and/or construct materials, ductwork, joints, transformations, splitters, dampers, and access doors as specified herein for the sheet metal ductwork as shown on Drawings.
1.4 SUBMITTALS
A. Shop Drawings: 1. Ductwork fabrication shop standards. 2. Seam and joint construction. 3. Duct accessories, including access doors and panels. 4. Hangers and supports, including methods for duct and building attachment, vibration isolation, and seismic restraints.
B. Welding certificates.
C. Field quality-control reports.
1.5 QUALITY ASSURANCE
A. Welding Qualifications: Qualify procedures and personnel according to AWS D9.1M/D9.1, "Sheet Metal Welding Code," for duct joint and seam welding.
CTA ARCHITECTS ENGINEERS METAL DUCTS JVWCD PAGE 15815 - 1 CENTRAL PIPELINE PROJECT B. NFPA Compliance: 1. NFPA 90A, "Installation of Air Conditioning and Ventilating Systems." 2. NFPA 90B, "Installation of Warm Air Heating and Air Conditioning Systems."
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. In other Part 2 articles where titles below introduce lists, the following requirements apply to product selection: 1. Manufacturers: Subject to compliance with requirements, provide products by one of the manufacturer's specified.
2.2 SHEET METAL MATERIALS
A. Comply with SMACNA's "HVAC Duct Construction Standards--Metal and Flexible" for acceptable materials, material thicknesses, and duct construction methods, unless otherwise indicated. Sheet metal materials shall be free of pitting, seam marks, roller marks, stains, discolorations, and other imperfections.
B. Galvanized Sheet Steel: Comply with ASTM A 653/A 653M. 1. Galvanized Coating Designation: G90 (Z275). 2. Finishes for Surfaces Exposed to View: Mill phosphatized.
C. Reinforcement Shapes and Plates: ASTM A 36/A 36M, steel plates, shapes, and bars; black and galvanized. 1. Where black- and galvanized-steel shapes and plates are used to reinforce aluminum ducts, isolate the different metals with butyl rubber, neoprene, or EPDM gasket materials.
D. Tie Rods: Galvanized steel, 1/4-inch (6-mm) minimum diameter for lengths 36 inches (900 mm) or less; 3/8-inch (10-mm) minimum diameter for lengths longer than 36 inches (900 mm).
2.3 SEALANT MATERIALS
A. Joint and Seam Sealants, General: The term "sealant is not limited to materials of adhesive or mastic nature but includes tapes and combinations of open-weave fabric strips and mastics.
B. Joint and Seam Tape: Not acceptable.
C. Tape Sealing System: Woven-fiber tape impregnated with gypsum mineral compound and modified acrylic/silicone activator to react exothermically with tape to form hard, durable, airtight seal.
D. Water-Based Joint and Seam Sealant: One-part flexible, adhesive sealant, resistant to UV light when cured, UL 723 listed, and complying with NFPA requirements for Class 1 ducts.
CTA ARCHITECTS ENGINEERS METAL DUCTS JVWCD PAGE 15815 - 2 CENTRAL PIPELINE PROJECT E. Solvent-Based Joint and Seam Sealant: One-part, nonsag, solvent-release-curing, polymerized butyl sealant formulated with a minimum of 75 percent solids.
F. Flanged Joint Mastic: One-part, acid-curing, silicone, elastomeric joint sealant complying with ASTM C 920, Type S, Grade NS, Class 25, use O.
G. Flange Gaskets: Butyl rubber or EPDM polymer with polyisobutylene plasticizer.
2.4 HANGERS AND SUPPORTS
A. Hanger Materials: Galvanized sheet steel or threaded steel rod. Use the following hangers and supports unless indicated otherwise on the drawings: 1. Hangers Installed in Influent Pump, Headworks buildings and other corrosive environments: Electrogalvanized, all-thread rods or galvanized rods with threads painted with zinc-chromate primer after installation. 2. Strap and Rod Sizes: Comply with SMACNA's "HVAC Duct Construction Standards--Metal and Flexible" for steel sheet width and thickness and for steel rod diameters. 3. Galvanized-steel straps attached to aluminum ducts shall have contact surfaces painted with zinc-chromate primer or shall be aluminum.
B. Duct Attachments: Sheet metal screws, blind rivets, or self-tapping metal screws; compatible with duct materials. Hardware on stainless steel ducts or aluminum shall be of same material as duct.
C. Trapeze and Riser Supports: Steel shapes complying with ASTM A 36/A 36M. 1. Supports for Galvanized-Steel Ducts: Galvanized-steel shapes and plates. 2. Supports for Stainless-Steel Ducts: Stainless-steel support materials. 3. Supports for Aluminum Ducts: Aluminum support materials unless materials are electrolytically separated from ducts.
2.5 RECTANGULAR DUCT FABRICATION
A. Fabricate ducts, elbows, transitions, offsets, branch connections, and other construction according to SMACNA's "HVAC Duct Construction Standards--Metal and Flexible" 2005 edition and complying with requirements for metal thickness, reinforcing types and intervals, tie-rod applications, and joint types and intervals. 1. Lengths: Fabricate rectangular ducts in lengths appropriate to reinforcement and rigidity class required for pressure class. 2. Deflection: Duct systems shall not exceed deflection limits according to SMACNA's "HVAC Duct Construction Standards--Metal and Flexible." 2005 edition.
B. Transverse Joints: Prefabricated slide-on joints and components constructed using manufacturer's guidelines for material thickness, reinforcement size and spacing, and joint reinforcement. 1. Manufacturers: a. Ductmate Industries, Inc. b. Nexus Inc. c. Ward Industries, Inc.
CTA ARCHITECTS ENGINEERS METAL DUCTS JVWCD PAGE 15815 - 3 CENTRAL PIPELINE PROJECT C. Formed-On Flanges: Construct according to SMACNA's "HVAC Duct Construction Standards--Metal and Flexible," – 2005 edition Figure 1-4, using corner, bolt, cleat, and gasket details. 1. Manufacturers: a. Ductmate Industries, Inc. b. Lockformer. 2. Duct Size: Maximum 30 inches (750 mm) wide and up to 2 inch wg (500 Pa) pressure class. 3. Longitudinal Seams: Pittsburgh lock sealed with noncuring polymer sealant (only on all medium and high pressure ductwork).
D. Cross Breaking or Cross Beading: Cross break or cross bead duct sides 12 inches (480 mm) and larger and 20 gage or less, with more than 10 sq. ft. (0.93 sq. m) of nonbraced panel area.
E. Transitions: 1. Do not exceed 1 inch in 4 inches of slope for decrease-in-area transitions, 1 inch in 7 inches is preferable. 2. Do not exceed 45 degrees on the entering or leaving side for angle of transitions at connections to equipment without the use of approved vanes.
F. Elbows: 1. Fabricate elbows using one of the following Specifications: The fabrication methods are listed in order of preference. Use radius elbows wherever possible. Use square elbows only when available space prevents the use of radius elbows. a. Unvaned, long radius elbow with the throat radius equal to 3/4 of the width of the duct and with a full heel radius. b. Six inch throat radius with full radius, single thickness vanes and full heel radius. c. Square elbows with airfoil, single thickness turning vanes. d. Maximum unsupported length of vanes shall be 36 inches. Securely fasten vanes to runners. Secure vanes in stable position. Construct vane edges to project tangents parallel to duct sides. 2. Turning Vanes: Refer to "Duct Accessories."
G. Branch Connections: Refer to SMACNA “HVAC Duct Construction Standards” 2005 Edition for figures listed in the following paragraphs. 1. Pressure Classification 2 Inches and Less: a. Rectangular branch from rectangular main: 45 degree entry with all corners closed as shown in Figure 4-6. b. Round branches: High-efficiency take-offs if shown on Drawings, otherwise use spin-in fitting without scoop. c. Parallel flow branches: See Figure 4-5. d. Space duct joints to avoid cutting them for branch take offs and outlet collars. 2. Pressure Classification Above 2 Inches: a. Round Branches: Conical round fittings only. b. Rectangular branch from rectangular main: 45 degree entry with all corners closed as shown in Figure 4-6. c. Parallel Flow Branches: See Figure 4-5.
CTA ARCHITECTS ENGINEERS METAL DUCTS JVWCD PAGE 15815 - 4 CENTRAL PIPELINE PROJECT d. Space duct joints to avoid cutting them for branch take offs and outlet collars.
2.6 ROUND DUCT AND FITTING FABRICATION
A. Round and Flat-Oval, Spiral Lock Seam Ducts: Fabricate supply ducts according to SMACNA's "HVAC Duct Construction Standards--Metal and Flexible." 1. Manufacturers: a. Accu-Duct. b. McGill AirFlow Corporation. c. Norlock. d. SEMCO Incorporated. e. Team Mechanical Inc. f. Ventline. g. West Cost Manufacturing. h. Sheet Metal Contractors, Inc.
B. Duct Joints: 1. Ducts up to 20 Inches (500 mm) in Diameter: Interior, center-beaded slip coupling, sealed before and after fastening, attached with sheet metal screws. 2. Ducts 21 to 72 Inches (535 to 1830 mm) in Diameter: Three-piece, gasketed, flanged joint consisting of two internal flanges with sealant and one external closure band with gasket. a. Manufacturers: 1) Ductmate Industries, Inc. 2) Lindlab Inc. 3) McGill AirFlow Corporation. 4) SEMCO Incorporated. 5) Sheet Metal Contractors, Inc.
C. 90 Degree Tees and Laterals and Conical Tees: Fabricate to comply with SMACNA's "HVAC Duct Construction Standards--Metal and Flexible," with metal thicknesses specified for longitudinal-seam straight ducts. Tees shall be conical. Saddle taps or straight tees shall not be used.
D. Diverging-Flow Fittings: Fabricate with reduced entrance to branch taps and with no excess material projecting from fitting onto branch tap entrance.
E. Two piece mitered elbows shall not be used.
F. The leading edge of all vanes in ducts over 20 inch diameter is to be hemmed with 1/2 inch foldback. Turning vanes in ducts over 24 inch are to be reinforced by stays or sectional construction to limit unsupported length to 24 inches. Vanes shall be minimum of 20 gauge.
G. Reduction of divided flow fittings to conical span section in the 36 common reductions in sizes 4 inch through 22 inch.
H. Galvanized areas damaged by welding to be coated with corrosion resistant aluminum paint.
CTA ARCHITECTS ENGINEERS METAL DUCTS JVWCD PAGE 15815 - 5 CENTRAL PIPELINE PROJECT I. Fabricate elbows using die-formed, gored, pleated, or mitered construction. Bend radius of die-formed, gored, and pleated elbows shall be 1-1/2 times duct diameter. Unless elbow construction type is indicated, fabricate elbows as follows: 1. Mitered-Elbow Radius and Number of Pieces: Welded construction complying with SMACNA's "HVAC Duct Construction Standards--Metal and Flexible," unless otherwise indicated. 2. Round Mitered Elbows: Welded construction with the following metal thickness for pressure classes from minus 2 to plus 2 inch wg (minus 500 to plus 500 Pa): a. Ducts 3 to 36 Inches (75 to 915 mm) in Diameter: 22 gage (0.85-mm). b. Ducts 37 to 50 Inches (940 to 1270 mm) in Diameter: 20 gage (1.0 mm). c. Ducts 52 to 60 Inches (1320 to 1525 mm) in Diameter: 18 gage (1.3 mm). d. Ducts 62 to 84 Inches (1575 to 2130 mm) in Diameter: 16 gage (1.6 mm). 3. Round Mitered Elbows: Welded construction with the following metal thickness for pressure classes from 2 to 10 inch wg (500 to 2500 Pa): a. Ducts 3 to 26 Inches (75 to 660 mm) in Diameter: 22 gage (0.85-mm). b. Ducts 27 to 50 Inches (685 to 1270 mm) in Diameter: 20 gage (1.0 mm). c. Ducts 52 to 60 Inches (1320 to 1525 mm) in Diameter: 18 gage (1.3 mm). d. Ducts 62 to 84 Inches (1575 to 2130 mm) in Diameter: 16 gage (1.6 mm). 4. Round Elbows 8 Inches (200 mm) and Less in Diameter: Fabricate die-formed elbows for 45 and 90 degree elbows and pleated elbows for 30, 45, 60, and 90 degrees only. Fabricate nonstandard bend-angle configurations or nonstandard diameter elbows with gored construction. 5. Round Elbows 9 through 14 Inches (225 through 355 mm) in Diameter: Fabricate gored or pleated elbows for 30, 45, 60, and 90 degrees unless space restrictions require mitered elbows. Fabricate nonstandard bend-angle configurations or nonstandard diameter elbows with gored construction. 6. Round Elbows Larger Than 14 Inches (355 mm) in Diameter: Fabricate gored elbows unless space restrictions require mitered elbows. 7. Die-Formed Elbows for Sizes through 8 Inches (200 mm) in Diameter and All Pressures 20 gage thick with 2-piece welded construction. 8. Round Gored-Elbow Metal Thickness: Same as non-elbow fittings specified above. 9. Flat-Oval Elbow Metal Thickness: Same as longitudinal-seam flat-oval duct specified above. 10. Pleated Elbows for Sizes through 14 Inches (355 mm) in Diameter and Pressures through 10 Inch wg (2500 Pa): 26 gage (0.55-mm).
PART 3 - EXECUTION
3.1 DUCT APPLICATIONS
A. Static-Pressure Classes: Unless otherwise indicated on the drawings, construct ducts according to the following: 1. Metal Ducts: Ducts shall be constructed to a SMACNA static pressure classification not less than the external static pressure indicated in the equipment schedules. For example if the fan serving a duct system is rated at 2” w.g. external static pressure; the ductwork connected to the suction of the fan shall have a SMACNA negative 2” pressure rating and any discharge ductwork shall have a SMACNA positive 2” w.g. static pressure rating. Duct applications shall
CTA ARCHITECTS ENGINEERS METAL DUCTS JVWCD PAGE 15815 - 6 CENTRAL PIPELINE PROJECT have the following minimum ratings unless the equipment schedules require higher ratings. a. Supply Ducts: 1 w.g. positive (Minimum) b. Return Ducts: 1/2 inch w.g. negative (Minimum) c. Exhaust Ducts: 1 inch negative (Minimum) d. Provide duct pressure class construction to match the greater of the above ratings or the connected equipment static pressure.
B. All ducts shall be galvanized steel except when indicated to be aluminum, stainless steel or PVC coated on the drawings. Refer to “Non-Metal” ducts for fiberglass ductwork.
3.2 DUCT INSTALLATION
A. Drawing plans, schematics, and diagrams indicate general location and arrangement of duct system. Indicated duct locations, configurations, and arrangements were used to size ducts and calculate friction loss for air-handling equipment sizing and for other design considerations. Install duct systems as indicated unless deviations to layout are approved on Shop Drawings and Coordination Drawings.
B. Install ducts according to SMACNA's "HVAC Duct Construction Standards - Metal and Flexible"-2005 edition unless otherwise indicated.
C. Install round ducts in maximum practical lengths.
D. Install ducts with fewest possible joints.
E. Install factory- or shop-fabricated fittings for changes in direction, size, and shape and for branch connections. Secure fittings with screws. Install screws at intervals of 10 inches, with a minimum of (3) screws per fitting. Seal all joints and seams.
F. Unless otherwise indicated, install ducts vertically and horizontally, and parallel and perpendicular to building lines.
G. Install ducts with a clearance of 1 inch (25 mm), plus allowance for insulation thickness.
H. Route ducts to avoid passing through transformer vaults and electrical equipment rooms and enclosures.
I. Where ducts pass through non-fire-rated interior partitions and exterior walls and are exposed to view, cover the opening between the partition and duct or duct insulation with sheet metal flanges of same metal thickness as the duct. Overlap openings on four sides by at least 1-1/2 inches (38 mm).
J. Protect duct interiors with sheet metal or plastic sheet covers from moisture, construction debris and dust, and other foreign materials until system is energized. Comply with SMACNA's "Duct Cleanliness for New Construction Guidelines," Intermediate Level.
K. Intermediate duct reinforcement to be same as duct material.
L. Do not exceed 45 degrees for easement transition angle.
CTA ARCHITECTS ENGINEERS METAL DUCTS JVWCD PAGE 15815 - 7 CENTRAL PIPELINE PROJECT M. Insulation: Where Drawings and Specifications require ducts to be insulated, make provisions for neat insulation finish around damper operating quadrants, splitter adjusting clamps, access doors, and similar operating devices. Metal collar equivalent in depth to insulation thickness and of suitable size to which insulation may be finished used for this purpose shall be attached to the duct. Linings in air ducts shall meet the Erosion Test Method described in UL Publication no. 181.
3.3 INSTALLATION OF EXPOSED DUCTWORK
A. Protect ducts exposed in finished spaces from being dented, scratched, or damaged.
B. Trim duct sealants flush with metal. Create a smooth and uniform exposed bead. Do not use two-part tape sealing system.
C. Grind welds to provide smooth surface free of burrs, sharp edges, and weld splatter. When welding stainless steel with a No. 3 or 4 finish, grind the welds flush, polish the exposed welds, and treat the welds to remove discoloration caused by welding.
D. Maintain consistency, symmetry, and uniformity in the arrangement and fabrication of fittings, hangers and supports, duct accessories, and air outlets.
E. Repair or replace damaged sections and finished work that does not comply with these requirements.
3.4 HANGER AND SUPPORT INSTALLATION
A. Comply with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible," Chapter 4, "Hangers and Supports."
B. Building Attachments: Concrete inserts, anchors, or structural-steel fasteners appropriate for construction materials to which hangers are being attached. 1. Where practical, install concrete inserts before placing concrete.
C. Hanger Spacing: Comply with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible," Table 4-1 (Table 4-1M), "Rectangular Duct Hangers Minimum Size," and Table 4-2, "Minimum Hanger Sizes for Round Duct," for maximum hanger spacing; install hangers and supports within 24 inches (610 mm) of each elbow and within 48 inches (1200 mm) of each branch intersection.
D. Hangers Exposed to View: Threaded rod and angle or channel supports.
E. Support vertical ducts with steel angles or channel secured to the sides of the duct with welds, bolts, sheet metal screws, or blind rivets; support at each floor and at a maximum intervals of 16 feet (5 m).
F. Install upper attachments to structures. Select and size upper attachments with pull-out, tension, and shear capacities appropriate for supported loads and building materials where used.
CTA ARCHITECTS ENGINEERS METAL DUCTS JVWCD PAGE 15815 - 8 CENTRAL PIPELINE PROJECT G. Support round ducts from building structure with galvanized steel hangers as recommended in SMACNA manual. Secure hangers to masonry portion of building by means of inserts or other acceptable anchors.
3.5 SEISMIC-RESTRAINT-DEVICE INSTALLATION
A. Install ducts with hangers and braces designed to support the duct and to restrain against seismic forces required by applicable building codes. Comply with ASCE/SEI 7. Refer to Section 15071 for additional seismic requirements.
B. Select seismic-restraint devices with capacities adequate to carry present and future static and seismic loads.
C. Install cables so they do not bend across edges of adjacent equipment or building structure.
D. Install cable restraints on ducts that are suspended with vibration isolators.
E. Install seismic-restraint devices using methods approved by an agency acceptable to authorities having jurisdiction.
F. Attachment to Structure: If specific attachment is not indicated, anchor bracing and restraints to structure, to flanges of beams, to upper truss chords of bar joists, or to concrete members.
G. Drilling for and Setting Anchors: 1. Identify position of reinforcing steel and other embedded items prior to drilling holes for anchors. Do not damage existing reinforcement or embedded items during drilling. Notify the Architect if reinforcing steel or other embedded items+ are encountered during drilling. Locate and avoid prestressed tendons, electrical and telecommunications conduit, and gas lines. 2. Do not drill holes in concrete or masonry until concrete, mortar, or grout has achieved full design strength. 3. Wedge Anchors: Protect threads from damage during anchor installation. Heavy-duty sleeve anchors shall be installed with sleeve fully engaged in the structural element to which anchor is to be fastened. 4. Set anchors to manufacturer's recommended torque, using a torque wrench. 5. Install zinc-coated steel anchors for interior applications and stainless-steel anchors for applications exposed to weather.
3.6 CONNECTIONS
A. Make connections to equipment with flexible connectors complying with Division 15 Section "Air Duct Accessories."
B. Comply with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible" for branch, outlet and inlet, and terminal unit connections.
CTA ARCHITECTS ENGINEERS METAL DUCTS JVWCD PAGE 15815 - 9 CENTRAL PIPELINE PROJECT 3.7 FIELD QUALITY CONTROL
A. Perform tests and inspections.
B. Duct System Cleanliness Tests: 1. Visually inspect duct system to ensure that no visible contaminants are present.
C. Prepare test and inspection reports.
3.8 AIR TEST AND BALANCE
A. Prepare the system for tests as specified in Section 15950 and correct deficiencies found by the Test and Balance firm.
END OF SECTION
CTA ARCHITECTS ENGINEERS METAL DUCTS JVWCD PAGE 15815 - 10 CENTRAL PIPELINE PROJECT SECTION 15820
DUCT ACCESSORIES
PART 1 - GENERAL
1.1 SUMMARY
A. This Section includes the following:
1. Volume dampers. 2. Turning vanes. 3. Flexible connectors. 4. Standard louvers. 5. Combination louvers. 6. Motorized dampers.
1.2 SUBMITTALS
A. Product Data: All products specified in this Section 15820.
1.3 QUALITY ASSURANCE
A. Comply with NFPA 90A, "Installation of Air Conditioning and Ventilating Systems."
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. In other Part 2 articles where titles below introduce lists, the following requirements apply to product selection:
1. Manufacturers: Subject to compliance with requirements, provide products by one of the manufacturers specified.
2.2 VOLUME DAMPERS
A. Manufacturers:
1. Air Balance, Inc. 2. Cesco Products. 3. McGill AirFlow Corporation. 4. Penn Ventilation Company, Inc. 5. Ruskin Company. 6. Vent Products Company, Inc.
B. General Description: Factory fabricated, with required hardware and accessories. Stiffen damper blades for stability. Include locking device to hold single-blade dampers
CTA ARCHITECTS ENGINEERS DUCT ACCESSORIES JVWCD PAGE 15820 - 1 CENTRAL PIPELINE PROJECT
in a fixed position without vibration. Close duct penetrations for damper components to seal duct consistent with pressure class.
1. Pressure Classes of 3 Inch wg or Higher: End bearings or other seals for ducts with axles full length of damper blades and bearings at both ends of operating shaft.
C. Standard Volume Dampers: Multiple- or single-blade, parallel- or opposed-blade design as indicated, standard leakage rating, and suitable for horizontal or vertical applications.
1. Aluminum Frames: Hat-shaped, 0.10-inch thick, aluminum sheet channels; frames with flanges where indicated for attaching to walls; and flangeless frames where indicated for installing in ducts. 2. Roll-Formed Aluminum Blades: 0.10-inch thick aluminum sheet. 3. Extruded-Aluminum Blades: 0.050-inch thick extruded aluminum. 4. Blade Axles: Nonferrous. 5. Bearings: Oil-impregnated bronze. 6. Tie Bars and Brackets: Aluminum.
2.3 TURNING VANES
A. Fabricate to comply with SMACNA's "HVAC Duct Construction Standards--Metal and Flexible" for vanes and vane runners. Vane runners shall automatically align vanes.
B. Manufactured Turning Vanes: Fabricate 1-1/2 inch wide, single vane up to 36 inch long, double blade above 36 inches, curved blades of galvanized sheet steel set 3/4-inch o.c.; support with bars perpendicular to blades set 2 inches o.c.; and set into vane runners suitable for duct mounting.
1. Manufacturers: a. Ductmate Industries, Inc. b. Duro Dyne Corp. c. METALAIRE, Inc.
2.4 FLEXIBLE CONNECTORS
A. Manufacturers:
1. Ductmate Industries, Inc. 2. Duro Dyne Corp. 3. Ventfabrics, Inc. 4. Ward Industries, Inc.
B. General Description: Flame-retardant or noncombustible fabrics, coatings, and adhesives complying with UL 181, Class 1.
C. Metal-Edged Connectors: Factory fabricated with a fabric strip 3-1/2 inches wide attached to two strips of 2-3/4 inch wide, 0.028-inch thick, galvanized sheet steel or 0.032-inch thick aluminum sheets. Select metal compatible with ducts.
CTA ARCHITECTS ENGINEERS DUCT ACCESSORIES JVWCD PAGE 15820 - 2 CENTRAL PIPELINE PROJECT
D. Indoor System, Flexible Connector Fabric: Glass fabric double coated with neoprene. Provide corrosion resistant fabric where indicated.
1. Minimum Weight: 26 oz./sq. yd.. 2. Tensile Strength: 480 lbf/inch in the warp and 360 lbf/inch in the filling. 3. Service Temperature: Minus 40 to plus 200 deg F.
2.5 STANDARD LOUVERS
A. Manufacturers:
1. Airline Products Co. 2. Airolite Co. 3. American Warming & Ventilating Inc. 4. Arrow United Industries, Inc. 5. Cesco Products. 6. Dowco Corp. 7. Louvers & Dampers, Inc. 8. Penn Ventilator Co., Inc. 9. Ruskin Mfg. Co. 10. United Air.
B. General: Provide manufacturer's standard louvers of size, shape, capacity and type indicated and as required for complete installation.
C. Finishes: Provide louvers with a baked enamel finish in a color selected by the Architect.
D. Substrate Compatibility: Provide louvers with frame and sill styles that are compatible with adjacent substrate, and that are specifically manufactured to fit into construction openings with accurate fit and adequate support, for weatherproof installation. Refer to general construction Drawings and Specifications for types of substrate, which will contain each type of louver.
E. Materials: Construct of aluminum extrusions, ASTM B 221, Alloy 6063-T5. Weld units or use stainless steel fasteners.
F. Louver Screens: On inside face of exterior louvers, provide 1/2-inch square mesh anodized aluminum wire bird screens mounted in removable extruded aluminum frames.
G. Sills: Provide formed metal sills of the same material and finish as the louver.
H. Mullions: Provide concealed horizontal and vertical mullions.
CTA ARCHITECTS ENGINEERS DUCT ACCESSORIES JVWCD PAGE 15820 - 3 CENTRAL PIPELINE PROJECT
2.6 COMBINATION LOUVERS
A. Manufacturers:
1. Airline Products Co. 2. Airolite Co. 3. American Warming & Ventilating Inc. 4. Arrow United Industries, Inc. 5. Cesco Products. 6. Dowco Corp. 7. Louvers & Dampers, Inc. 8. Penn Ventilator Co., Inc. 9. Ruskin Mfg. Co.
B. Fabrication: 1. Frame: a. Material: Extruded aluminum, Alloy 6063- T5. b. Wall Thickness: 0.081 inch (2.1 mm), nominal. c. Depth: 6 inches (152 mm). d. Construction: Standard box frame. 2. Louver Blades: a. Style: Stationary, drainable. b. Material: Extruded aluminum, Alloy 6063- T5. c. Wall Thickness: 0.081 inch (2.1 mm), nominal. d. Angle: 37.5 degrees. e. Centers: 4 inches (102 mm), nominal. 3. Backdraft Damper Blades: a. Style: Gravity. b. Material: Roll formed aluminum. c. Wall Thickness: 0.025 inch (0.6 mm), nominal. 4. Bird Screen: a. Material: Aluminum, 1/2 inch mesh x 0.063 inch (13 mm mesh x 1.6 mm), intercrimp. b. Frame: Removable, re-wireable. 5. Seals: Synthetic seals mounted on louver blade edges to provide quiet operation. 6. Assembly: Factory assemble louver components.
C. Performance Data:
1. Based on testing 48 inch x 48 inch (1,219 mm x 1,219 mm) size unit in accordance with AMCA 500. 2. Free Area: 45 percent, nominal.
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D. Design Load: Incorporate structural supports required to withstand wind load from a 100 mph wind.
E. Finish: Provide louvers with a baked enamel finish in a color selected by the Architect.
2.7 MOTORIZED DAMPERS
A. Manufacturers:
1. Alerton Inc. by Wilson-Mohr (Applied Automation). 2. Andover Controls Corporation. 3. Honeywell International Inc., by Heath Engineers. 4. Johnson Controls, Inc. 5. Siemens Building Technologies, Inc. 6. Ruskin.
B. Dampers: AMCA-rated, parallel-blade design; 0.108-inch (2.8 mm) minimum thick, galvanized-steel or 0.125-inch (3.2 mm) minimum thick, extruded-aluminum frames with holes for duct mounting; damper blades shall not be less than 0.064-inch (1.6 mm) thick galvanized steel with maximum blade width of 8 inches (200 mm) and length of 48 inches (1220 mm).
1. Secure blades to 1/2-inch (13 mm) diameter, zinc-plated axles using zinc-plated hardware, with oil-impregnated sintered bronze lade bearings, blade-linkage hardware of zinc-plated steel and brass, ends sealed against spring-stainless- steel blade bearings, and thrust bearings at each end of every blade. 2. Operating Temperature Range: From minus 40 to plus 200 deg F (minus 40 to plus 93 deg C). 3. Edge Seals, Standard Pressure Applications: Closed-cell neoprene. 4. Edge Seals, Low-Leakage Applications: Use inflatable blade edging or replaceable rubber blade seals and spring-loaded stainless-steel side seals, rated for leakage at less than 10 cfm per sq. ft. (50 L/s per sq. m) of damper area, at differential pressure of 4-inch wg (1000 Pa) when damper is held by torque of 50 in. x lbf (5.6 N x m); when tested according to AMCA 500D.
PART 3 - EXECUTION
3.1 APPLICATION AND INSTALLATION
A. Install duct accessories according to applicable details in SMACNA's "HVAC Duct Construction Standards--Metal and Flexible" for metal ducts.
B. Provide duct accessories of materials suited to duct materials; use galvanized-steel accessories in galvanized-steel and fibrous-glass ducts, stainless-steel accessories in stainless-steel ducts, and aluminum accessories in aluminum ducts.
C. Provide balancing dampers at points on supply, return, and exhaust systems where branches lead from larger ducts as required for air balancing. Install at a minimum of two duct widths from branch takeoff.
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D. Install turning vanes in all square and rectangular elbows.
E. Install louvers in accordance with manufacturer’s instructions and details for a weatherproof system. Caulk perimeter with color matched non-shrink and non- hardening caulk. Coordinate installation with General Contractor and architectural installation details.
F. Install motorized dampers per manufacturer's written installation instructions.
3.2 ADJUSTING
A. Adjust duct accessories for proper settings.
B. Final positioning of manual-volume dampers is specified in Division 15 Section "Testing, Adjusting, and Balancing."
END OF SECTION
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SECTION 15838 POWER VENTILATORS
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section includes the following:
1. Ceiling-mounting ventilators. 2. Propeller fans.
1.3 PERFORMANCE REQUIREMENTS
A. Project Altitude: Base fan-performance ratings on actual Project site elevations.
1.4 SUBMITTALS
A. Product Data: Include rated capacities, furnished specialties, and accessories for each type of product indicated and include the following:
1. Certified fan performance curves with system operating conditions indicated. 2. Certified fan sound-power ratings. 3. Motor ratings and electrical characteristics, plus motor and electrical accessories. 4. Material thickness and finishes, including color charts. 5. Fan speed controllers.
B. Shop Drawings: Detail equipment assemblies and indicate dimensions, weights, loads, required clearances, method of field assembly, components, and location and size of each field connection.
1. Wiring Diagrams: Power, signal, and control wiring.
C. Operation and Maintenance Data: For power ventilators to include in emergency, operation, and maintenance manuals.
1.5 QUALITY ASSURANCE
A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use.
B. AMCA Compliance: Products shall comply with performance requirements and shall be licensed to use the AMCA-Certified Ratings Seal.
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C. NEMA Compliance: Motors and electrical accessories shall comply with NEMA standards.
D. UL Standard: Power ventilators shall comply with UL 705.
1.6 DELIVERY, STORAGE, AND HANDLING
A. Deliver fans as factory-assembled unit, to the extent allowable by shipping limitations, with protective crating and covering.
B. Disassemble and reassemble units, as required for moving to final location, according to manufacturer's written instructions.
C. Lift and support units with manufacturer's designated lifting or supporting points.
1.7 COORDINATION
A. Coordinate size and location of structural-steel support members.
B. Coordinate size and location of concrete bases. Cast anchor-bolt inserts into bases. Concrete, reinforcement, and formwork requirements are specified in Division 3.
PART 2 - PRODUCTS
2.1 CEILING-MOUNTING VENTILATORS
A. Manufacturers: Subject to compliance with requirements, provide products by one of the following:
1. ACME Engineering and Manufacturing Company. 2. Carnes Company HVAC. 3. Loren Cook Company. 4. New York Blower Company (The). 5. Penn Ventilation. 6. Greenheck Fan Corp.
B. Description: Centrifugal fans designed for installing in ceiling or wall or for concealed in- line applications.
C. Housing: Steel, lined with acoustical insulation.
D. Fan Wheel: Centrifugal wheels directly mounted on motor shaft. Fan shrouds, motor, and fan wheel shall be removable for service.
E. Grille: Painted aluminum, louvered grille with flange on intake and thumbscrew attachment to fan housing.
F. Electrical Requirements: Junction box for electrical connection on housing and receptacle for motor plug-in.
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G. Accessories:
1. Manufacturer's standard roof jack or wall cap, and transition fittings.
2.2 PROPELLER FANS
A. Manufacturers: Subject to compliance with requirements, provide products by one of the following:
1. ACME Engineering and Manufacturing Co. 2. Carnes Company HVAC. 3. Loren Cook Company. 4. New York Blower Company (The). 5. Penn Ventilation. 6. Greenheck Fan Corp. 7. Twin City Fan
B. Description: Direct- or belt-driven propeller fans consisting of fan blades, hub, housing, orifice ring, motor, drive assembly, and accessories. Fans shall be manufactured at an ISO 9001 certified facility. Fans shall be UL listed (UL 705) and bear the AMCA certified ratings seal for sound and air performance.
C. Housing: The fan shall be of bolted and welded construction utilizing corrosion resistant fasteners. The motor, bearings and drives shall be mounted on a 14 gauge steel power assembly. The power assembly shall be bolted to a minimum 14 gauge wall panel with continuously welded corners and an integral venturi. Unit shall bear an engraved aluminum nameplated.
D. Propeller: Propeller shall be a high-efficiency fabricated steel or extruded aluminum airfoil design as scheduled. Aluminum wheels shall be secured to a cast aluminum hub and steel wheels shall be secured to a 7 gauge steel hub. The hub shall be keyed and locked to the shaft with two setscrews or a taper lock bushing. Propeller shall be balanced in accordance with AMCA standard 204-96.
E. Motor: Heavy duty type with permanently lubricated sealed ball bearings. Motors shall be open drip proof unless stated otherwise on the drawings. Motors greater than ¾ HP shall be NEMA "Premium" Efficient type
F. Belt-Driven Drive Assembly: Resiliently mounted to housing, statically and dynamically balanced and selected for continuous operation at maximum rated fan speed and motor horsepower, with final alignment and belt adjustment made after installation.
1. Service Factor Based on Fan Motor Size: 1.4. 2. Fan Shaft: Turned, ground, and polished steel; keyed to wheel hub. 3. Bearings: Heavy duty re-greasable ball type in a cast iron pillow block housing selected for a minimum L50 life in excess of 200,000 hours at maximum cataloged operating speed. 4. Pulleys: Cast iron with split, tapered bushing; dynamically balanced at factory.
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5. Motor Pulleys: Adjustable pitch for use with motors through 5 hp; fixed pitch for use with larger motors. Select pulley so pitch adjustment is at the middle of adjustment range at fan design conditions. 6. Belts: Oil resistant, nonsparking, and nonstatic; matched sets for multiple belt drives. 7. Belt Guards: Fabricate of steel for motors mounted on outside of fan cabinet.
G. Coating: All steel fan components shall have an electrostatically applied baked epoxy powder coating.
H. Accessories:
1. Gravity Shutters: Aluminum blades in aluminum frame; interlocked blades with nylon bearings. Provide only when indicated on drawings. Wall Pack type fans require gravity shutters. 2. Motor-Side Back Guard: Galvanized steel, complying with OSHA specifications, removable for maintenance. 3. Wall Sleeve: Galvanized steel to match fan and accessory size. Provide only when indicated on drawings. Wall Pack type fan require gravity shutters. 4. Explosion proof motor when indicated on drawings.
2.3 MOTORS
A. Enclosure Type: Open drip-proof unless indicated otherwise. All power ventilator motors greater than 3/4 HP shall be NEMA “Premium Efficient”
2.4 SOURCE QUALITY CONTROL
A. Sound-Power Level Ratings: Comply with AMCA 301, "Methods for Calculating Fan Sound Ratings from Laboratory Test Data." Factory test fans according to AMCA 300, "Reverberant Room Method for Sound Testing of Fans." Label fans with the AMCA- Certified Ratings Seal.
B. Fan Performance Ratings: Establish flow rate, pressure, power, air density, speed of rotation, and efficiency by factory tests and ratings according to AMCA 210, "Laboratory Methods of Testing Fans for Rating."
PART 3 - EXECUTION
3.1 INSTALLATION
A. Install power ventilators level and plumb.
B. Ceiling Units: Suspend units from structure; use steel wire or metal straps.
C. Support suspended units from structure using threaded steel rods and spring hangers having a static deflection of 1 inch.
D. Install units with clearances for service and maintenance.
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E. Label units according to requirements specified in Division 15 Section "Mechanical Identification."
F. Install power ventilators per manufacturer's written installation instructions.
3.2 CONNECTIONS
A. Duct installation and connection requirements are specified in other Division 15 Sections. Drawings indicate general arrangement of ducts and duct accessories. Make final duct connections with flexible connectors. Flexible connectors are specified in Division 15 Section "Duct Accessories."
B. Install ducts adjacent to power ventilators to allow service and maintenance.
C. Ground equipment according to Division 16 Section "Grounding and Bonding."
D. Connect wiring according to Division 16 Section "Conductors and Cables."
3.3 FIELD QUALITY CONTROL
A. Perform the following field tests and inspections and prepare test reports:
1. Verify that shipping, blocking, and bracing are removed. 2. Verify that unit is secure on mountings and supporting devices and that connections to ducts and electrical components are complete. Verify that proper thermal-overload protection is installed in motors, starters, and disconnect switches. 3. Verify that cleaning and adjusting are complete. 4. Disconnect fan drive from motor, verify proper motor rotation direction, and verify fan wheel free rotation and smooth bearing operation. Reconnect fan drive system, align and adjust belts, and install belt guards. 5. Adjust belt tension. 6. Adjust damper linkages for proper damper operation. 7. Verify lubrication for bearings and other moving parts. 8. Verify that manual and automatic volume control and fire and smoke dampers in connected ductwork systems are in fully open position. 9. Disable automatic temperature-control operators, energize motor and adjust fan to indicated rpm, and measure and record motor voltage and amperage. 10. Shut unit down and reconnect automatic temperature-control operators. 11. Remove and replace malfunctioning units and retest as specified above.
B. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment.
3.4 ADJUSTING
A. Adjust damper linkages for proper damper operation.
B. Adjust belt tension.
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C. Refer to Division 15 Section "Testing, Adjusting, and Balancing" for testing, adjusting, and balancing procedures.
D. Replace fan and motor pulleys as required to achieve design airflow.
E. Lubricate bearings.
END OF SECTION
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SECTION 15855 DIFFUSERS, REGISTERS, AND GRILLES
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section includes diffusers, registers, and grilles for all HVAC systems.
1.3 SUBMITTALS
A. Product Data: For each model indicated, include the following:
1. Data Sheet: For each type of air outlet and inlet, and accessory furnished; indicate construction, finish, color and mounting details. Include materials and methods of assembly. 2. Performance Data: Include throw and drop, static-pressure drop, and noise ratings for each type of air outlet and inlet.
1.4 QUALITY ASSURANCE
A. Product Options: Drawings and schedules indicate specific requirements of diffusers, registers, and grilles and are based on the specific requirements of the systems indicated. Other manufacturers' products with equal performance characteristics may be considered.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. Manufacturers: Subject to compliance with requirements, provide products by one of the following:
1. Anemostat. 2. Carnes. 3. Hart & Coolie. 4. Krueger. 5. METALAIRE, Inc. 6. Titus.
2.2 SOURCE QUALITY CONTROL
A. Testing: Test performance according to ASHRAE 70, "Method of Testing for Rating the Performance of Air Outlets and Inlets."
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PART 3 - EXECUTION
3.1 EXAMINATION
A. Examine areas where diffusers, registers, and grilles are to be installed for compliance with requirements for installation tolerances and other conditions affecting performance of equipment. Do not proceed with installation until unsatisfactory conditions have been corrected.
3.2 INSTALLATION
A. Install diffusers, registers, and grilles level and plumb, according to manufacturer's written instructions, Coordination Drawings, original design, and referenced standards.
B. Ceiling-Mounted Outlets and Inlets: Drawings indicate general arrangement of ducts, fittings, and accessories. Air outlet and inlet locations have been indicated to achieve design requirements for air volume, noise criteria, airflow pattern, throw, and pressure drop. Make final locations where indicated, as much as practicable. For units installed in lay-in ceiling panels, locate units in the center of the panel. Where architectural features or other items conflict with installation, notify Architect for a determination of final location.
C. Install diffusers, registers, and grilles with airtight connection to ducts and to allow service and maintenance of dampers, air extractors, and fire dampers.
3.3 ADJUSTING
A. After installation, adjust diffusers, registers, and grilles to air patterns indicated, or as directed, before starting air balancing.
3.4 CLEANING
A. After installation of diffusers, registers, and grilles, inspect exposed finish. Clean exposed surfaces to remove burrs, dirt, and smudges. Replace diffusers, registers, and grilles that have damaged finishes.
END OF SECTION
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SECTION 15950 TESTING, ADJUSTING, AND BALANCING
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section includes TAB to produce design objectives for all air systems.
1.3 SUBMITTALS
A. Qualification Data: Within 30 days from Contractor's Notice to Proceed, submit 2 copies of evidence that TAB firm and this Project's TAB team members meet the qualifications specified in "Quality Assurance" Article.
B. Contract Documents Examination Report: Within 45 days from Contractor's Notice to Proceed, submit 2 copies of the Contract Documents review report as specified in Part 3.
C. Sample Report Forms: Submit two sets of sample TAB report forms.
1.4 QUALITY ASSURANCE
A. TAB Firm Qualifications: Engage a TAB firm certified by either AABC or NEBB.
B. The Test and Balance Contractor shall be an independent consultant. The firm shall be independent of all Contractors including the Mechanical and Temperature Controls Contractor.
C. TAB Conference: Meet with Owner's and Engineer's representatives to develop a mutual understanding of the details. Ensure the participation of TAB team members, equipment manufacturers' authorized service representatives, HVAC controls installers, and other support personnel. Provide seven days' advance notice of scheduled meeting time and location.
1. Agenda Items: Include at least the following: a. Submittal distribution requirements. b. The Contract Documents examination report. c. TAB plan. d. Work schedule and Project-site access requirements. e. Coordination and cooperation of trades and subcontractors. f. Coordination of documentation and communication flow.
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D. Certification of TAB Reports: Certify TAB field data reports. This certification includes the following:
1. Review field data reports to validate accuracy of data and to prepare certified TAB reports. 2. Certify that TAB team complied with approved TAB plan and the procedures specified and referenced in this Specification.
E. TAB Report Forms: Use standard forms from NEBB's "Procedural Standards for Testing, Adjusting, and Balancing of Environmental Systems." Or from SMACNA's "HVAC Systems - Testing, Adjusting, and Balancing."
F. Instrumentation Calibration: Calibrate instruments at least every six months or more frequently if required by instrument manufacturer.
1. Keep an updated record of instrument calibration that indicates date of calibration and the name of party performing instrument calibration.
1.5 COORDINATION
A. Coordinate the efforts of factory-authorized service representatives for systems and equipment, HVAC controls installers, and other mechanics to operate HVAC systems and equipment to support and assist TAB activities.
B. Notice: Provide seven days' advance notice for each test. Include scheduled test dates and times.
PART 2 - PRODUCTS (NOT APPLICABLE)
PART 3 - EXECUTION
3.1 EXAMINATION
A. Examine the Contract Documents to become familiar with Project requirements and to discover conditions in systems' designs that may preclude proper TAB of systems and equipment.
1. Verify that balancing devices, such as test ports, gage cocks, thermometer wells, flow-control devices, balancing valves and fittings, and manual volume dampers, are required by the Contract Documents. Verify that quantities and locations of these balancing devices are accessible and appropriate for effective balancing and for efficient system and equipment operation.
B. Examine system and equipment installations to verify that they are complete and that testing, cleaning, adjusting, and commissioning specified in individual Sections have been performed.
C. Examine HVAC system and equipment installations to verify that indicated balancing devices, such as test ports, gage cocks, thermometer wells, flow-control devices, balancing valves and fittings, and manual volume dampers, are properly installed, and
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that their locations are accessible and appropriate for effective balancing and for efficient system and equipment operation.
D. Examine systems for functional deficiencies that cannot be corrected by adjusting and balancing.
E. Examine HVAC equipment to ensure that clean filters have been installed, bearings are greased, belts are aligned and tight, and equipment with functioning controls is ready for operation.
F. Examine equipment for installation and for properly operating safety interlocks and controls.
G. Report deficiencies discovered before and during performance of TAB procedures. Observe and record system reactions to changes in conditions. Record default set points if different from indicated values.
3.2 PREPARATION
A. Complete system readiness checks and submit a system readiness report to the Project Engineer. Verify the following:
1. Permanent electrical power wiring is complete. 2. Equipment and duct access doors are securely closed. 3. Balance is open. 4. Ceilings are installed in critical areas where air-pattern adjustments are required and access to balancing devices is provided. 5. Windows and doors can be closed so indicated conditions for system operations can be met.
3.3 GENERAL PROCEDURES FOR TESTING AND BALANCING
A. Perform testing and balancing procedures on each system according to the procedures contained in NEBB's "Procedural Standards for Testing, Adjusting, and Balancing of Environmental Systems" or SMACNA's "HVAC Systems - Testing, Adjusting, and Balancing" and this Section.
B. Cut insulation, ducts, pipes, and equipment cabinets for installation of test probes to the minimum extent necessary to allow adequate performance of procedures. After testing and balancing, close probe holes and patch insulation with new materials identical to those removed. Restore vapor barrier and finish according to insulation Specifications for this Project.
C. Mark equipment and balancing device settings with paint or other suitable, permanent identification material, including damper-control positions, valve position indicators, fan- speed-control levers, and similar controls and devices, to show final settings.
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3.4 GENERAL PROCEDURES FOR BALANCING AIR SYSTEMS
A. Prepare test reports for both fans and outlets. Obtain manufacturer's outlet factors and recommended testing procedures. Crosscheck the summation of required outlet volumes with required fan volumes.
B. Determine the best locations in main and branch ducts for accurate duct airflow measurements.
C. Check airflow patterns from the outside-air louvers and dampers and the return- and exhaust-air dampers, through the supply-fan discharge and mixing dampers.
D. Verify that motor starters are equipped with properly sized thermal protection.
E. Check dampers for proper position to achieve desired airflow path.
F. Check for airflow blockages.
G. Check condensate drains for proper connections and functioning.
H. Check for proper sealing of air-handling unit components.
I. Check for proper sealing of air duct system.
3.5 TOLERANCES
A. Set HVAC system airflow and water flow rates within the following tolerances:
1. Supply, Return, and Exhaust Fans and Equipment with Fans: Plus 5 to plus 10 percent. 2. Air Outlets and Inlets: 0 to minus 10 percent.
3.6 FINAL REPORT
A. General: Typewritten, or computer printout in letter-quality font, on standard bond paper, in three-ring binder, tabulated and divided into sections by tested and balanced systems.
B. Include a certification sheet in front of binder signed by the testing and balancing engineer.
1. Include a list of instruments used for procedures, along with proof of calibration.
C. General Report Data: In addition to form titles and entries, include the following data in the final report, as applicable:
1. Title page. 2. Name and address of TAB firm. 3. Project name. 4. Project location. 5. Architect's/Engineer’s name and address.
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6. Contractor's name and address. 7. Report date. 8. Signature of TAB firm who certifies the report. 9. Table of Contents with the total number of pages defined for each section of the report. Number each page in the report. 10. Summary of contents including the following: a. Indicated versus final performance. b. Notable characteristics of systems. c. Description of system operation sequence if it varies from the Contract Documents.
11. Notes to explain why certain final data in the body of reports varies from indicated values. 12. Test conditions for fans and pump performance forms including the following: a. Settings for outside-, return-, and exhaust-air dampers. b. Conditions of filters. c. Cooling coil, wet- and dry-bulb conditions. d. Face and bypass damper settings at coils. e. Fan drive settings including settings and percentage of maximum pitch diameter. f. Inlet vane settings for variable-air-volume systems. g. Settings for supply-air, static-pressure controller. h. Other system operating conditions that affect performance. 3.7 ADDITIONAL TESTS
A. Within 90 days of completing TAB, perform additional testing and balancing to verify that balanced conditions are being maintained throughout and to correct unusual conditions.
B. Seasonal Periods: If initial TAB procedures were not performed during near-peak summer and winter conditions, perform additional testing, inspecting, and adjusting during near-peak summer and winter conditions.
END OF SECTION
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DIVISION 16 ELECTRICAL
SECTION 16050 ELECTRICAL GENERAL PROVISIONS
PART 1 – GENERAL
1.1 THE REQUIREMENT
A. The CONTRACTOR shall provide electrical and appurtenant Work necessary for a complete and operable electrical system, in accordance with the Contract Documents.
B. Make all field connections and terminations to all motors, switchgear, panels, control equipment and devices, instruments, and to all vendor-furnished packaged equipment. The requirements of this Section shall apply to all electrical items indicated in the various Sections of Division 16 unless otherwise indicated.
C. Provide all materials and incidentals required to complete the electrical work. Typical materials, which may be incidentals are terminal lugs not furnished with vendor-supplied equipment, compression connectors for cables, splices, junction and terminal boxes, and all control wires required by vendor-furnished equipment to interconnect with other equipment all specifically indicated on the Contract Documents.
D. All concrete work required for encasement, installation, or construction of the Work specified in the various Sections of Division 16 shall be 3,000-psi concrete, and the following requirements shall apply:
1. Consolidation of encasement concrete around duct banks shall be by hand puddling, and no mechanical vibration shall be permitted. 2. A workability admixture shall be used in encasement concrete, which shall be a hydroxylated carboxylic acid type in liquid form. Admixtures containing calcium chloride shall not be used. 3. Concrete used to encase conduits shall be made with gravel containing rocks ¾ inch in size or less. It shall be wet enough to flow easily into the spaces around the conduits, but not so fluid as to float the conduits. 4. Concrete for encasement of conduit or duct banks shall contain an integral red- oxide coloring pigment in the proportion of 8 pounds per cubic yard of concrete.
1.2 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS
A. Codes and Standards
NEC National Electrical Code, latest edition
B. Government Standards
FS W-C-596E/GEN(1) Connector, Plug, Receptacle and Cable Outlet, Electrical Power
FS W-S-896E/GEN(1) Switches, Toggle (Toggle and Lock), Flush Mounted (ac)
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-1 CENTRAL PIPELINE PROJECT FS WW-C-581D, E Conduit, Metal, Rigid, And Intermediate; And Coupling, Elbow, and Nipple, Electrical Conduit: Steel, Zinc Coated
OSHA Safety and Health Standards, 29 CFR 1910 and 29 CFR 1926 as applicable
C. Commercial Standards
ANSI C80.1 Zinc Coated, Rigid Steel Conduit, Specification for
ANSI C80.4 Fittings for Rigid Metal Conduit and Electrical Metallic Tubing, Specifications for
ANSI/UL 467 Grounding and Bonding Equipment, Safety Standard for
ASTM B 3 Soft or Annealed Copper Wire
ASTM B 8 Specification for Concentric-Lay-Stranded Copper Conductors, Hard, Medium-Hard, and Soft
ASTM B 33 Specification for Tinned Soft or Annealed Cooper Wire for Electrical Purposes
ICEA S-61-402 Thermoplastic - Insulated Wire and Cable
ICEA S-68-516, NEMA WC8 Ethylene Propylene Rubber Insulated Wire and Cable
NEMA 250 Enclosures for Electrical Equipment (1,000 volts maximum)
NEMA PB-1 Panelboards
UL 6 Rigid Metal Electrical Conduit
UL 514 Electrical Outlet Boxes and Fittings
D. All equipment furnished by the CONTRACTOR shall be listed by and shall bear the label of Underwriters' Laboratories, Incorporated, (UL) or an independent testing laboratory acceptable to the local Code-enforcement agency having jurisdiction.
E. The construction and installation of all electrical equipment and materials shall comply with all applicable provisions of the OSHA Safety and Health Standards (29CFR1910 and 29CFR1926, as applicable), State Building Standards, and applicable local codes and regulations.
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-2 CENTRAL PIPELINE PROJECT 1.3 PERMITS AND INSPECTION
A. Permits shall be obtained and inspection fees shall be paid for as indicated in Article 6.06 of the General Conditions.
1.4 CONTRACTOR SUBMITTALS
A. Shop Drawings and Catalog Data: Submit shop drawings and catalog data submittals in accordance with Section 01300 - Contractor Submittals.
B. Submit complete material lists for the Work of this Section. Such lists shall state manufacturer and brand name of each item or class of material. Submit shop drawings for all grounding work not specifically indicated.
C. Shop drawings are required for materials and equipment listed in other sections. Shop drawings shall provide sufficient information to evaluate the suitability of the proposed material or equipment for the intended use, and for compliance with these Specifications. The following shall be included:
1. Front, side, rear elevations and top views with dimensional data. 2. Location of conduit entrances and access plates. 3. Component data. 4. Connection diagrams, terminal numbers, wire numbers, internal wiring diagrams, conductor size, and cable numbers. 5. Method of anchoring, seismic requirement; weight. 6. Types of materials and finish. 7. Nameplates. 8. Temperature limitations, as applicable. 9. Voltage requirement, as applicable. 10. Front and rear access requirements.
D. Catalog data shall be submitted to supplement all shop drawings. Catalog cuts, bulletins, brochures, or the like or photocopies of applicable pages thereof shall be submitted for mass produced, noncustom manufactured material. These catalog data sheets shall be stamped to indicate the project name, applicable Specification section and paragraph, model number, and options. This information shall be marked in spaces designated for such data in the stamp.
E. Materials and Equipment Schedules: Furnish within 30 days, a complete list of all materials, equipment, apparatus, and fixtures proposed for use. The list shall include type, sizes, names of manufacturers, catalog numbers, and such other information required to identify the items.
F. O&M Manuals: Furnish manuals as part of the shop drawing submittals under "Operation and Maintenance Manuals" in Section 01300 - Contractor Submittals.
G. Record Drawings: In addition to the record drawings as a part of the record drawing requirements specified in Section 01300 – Contractor Submittals, show depths and routing of all duct bank concealed below grade electrical installations. Said set of record drawings shall be available to the ENGINEER during construction. After final inspection,
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-3 CENTRAL PIPELINE PROJECT transfer all record drawing information using a red pen to a set of drawings which shall then be delivered to the ENGINEER. In addition, the record drawings shall show all variations between the Work as actually constructed and as originally shown on the Drawings, based upon information supplied by the CONTRACTOR.
1.5 QUALITY ASSURANCE
A. Field Control of Location and Arrangement: The Drawings diagrammatically indicate the desired location and arrangement of outlets, conduit runs, equipment, and other items. Determine exact locations in the field based on the physical size and arrangement of equipment, finished elevations, and other obstructions. Locations shown on the Drawings, however, shall be adhered to as closely as possible.
B. All conduit and equipment shall be installed in such a manner as to avoid all obstructions and to preserve head room and keep openings and passageways clear. Lighting fixtures, switches, convenience outlets, and similar items shall be located within finished rooms, as shown. Where the Drawings do not indicate exact locations, such locations shall be obtained from the ENGINEER. Where equipment is installed without instruction and must be moved, it shall be moved without additional cost to the OWNER.
C. Workmanship: All materials and equipment shall be installed in accordance with printed recommendations of the manufacturer which have been reviewed by the ENGINEER. The installation shall be accomplished by workmen skilled in this type of work and installation shall be coordinated in the field with other trades so that interferences are avoided.
D. All Work, including installation, connection, calibration, testing, adjustment, and paint touchup, shall be accomplished by qualified, experienced personnel working under continuous, competent supervision. The completed installation shall display competent work, reflecting adherence to prevailing industrial standards and methods.
E. Protection of Equipment and Materials: Furnish adequate means for and shall fully protect all finished parts of the materials and equipment against damage from any cause during the progress of the Work and until acceptable by the ENGINEER.
F. All materials and equipment, both in storage and during construction, shall be covered in such a manner that no finished surfaces will be damaged, marred, or splattered with water, foam, plaster, or paint. All moving parts shall be kept clean and dry.
G. Replace or have refinished by the manufacturer, all damaged materials or equipment, including face plates of panels and switchboard sections, at no expense to the OWNER.
H. Tests: Perform all tests required by the ENGINEER or other authorities having jurisdictions. All such tests shall be performed in the presence of the ENGINEER. Furnish all necessary testing equipment and pay all costs of tests, including all replacement parts and labor necessary due to damage resulting from damaged
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-4 CENTRAL PIPELINE PROJECT equipment or from test and correction of faulty installation. The following testing shall be accomplished:
1. Insulation resistance tests under "Wire and Cable," below. 2. Operational testing of all equipment furnished and/or connected in other Sections of Division 16, including furnishing of support labor for testing.
I. Standard test reports for mass-produced equipment shall be submitted along with the shop drawing for such equipment. Test reports on testing specifically required for individual pieces of equipment shall be submitted for review prior to final acceptance of the project.
J. Any test failure shall be corrected in accordance with the industry practices and in a manner satisfactory to the ENGINEER.
1.6 AREA DESIGNATIONS
A. General: For purposes of delineating electrical enclosure and electrical installation requirements of this project, certain areas have been classified in the Contract Documents as defined below. Electrical installations within these areas shall conform to the referenced code requirements for the area involved.
B. General Purpose Indoor Locations: Electrical work installed in areas which are not otherwise specifically classified shall be "General Purpose." Workmanship and enclosures shall comply with the general requirements of these Specifications. Electrical enclosures shall be NEMA Type 12.
C. Outdoor and Damp Locations: In outdoor locations, raceway shall be rigid galvanized steel (GRS) conduit; entrances shall be threaded; and fittings shall have gasketed covers. Provisions shall be made to drain the fitting or conduit system. Threaded fastening hardware shall be stainless steel. Raceway supports such as hanger rods, clamps, and brackets shall be galvanized. Attachments or welded assemblies shall be galvanized after fabrication. Instruments and control cabinets shall be NEMA Type 4X. Switchboards, motor control centers, and panel enclosures shall be weatherproof NEMA Type 3R. Enclosures shall be mounted 1 inch from walls to provide an air space. Locations which are indoors and 2 feet below grade elevation or which are classified as damp locations on the Drawings shall have electrical installations which conform to the requirements for outdoor locations. "Damp locations" shall include pipe galleries, tunnels, vaults, and basements. All rooms housing liquid handling equipment are also classified as damp locations regardless of grade elevation.
D. Vaults with forced air ventilation are not considered “damp locations”. NEMA Type 12 panels will be required in these areas
E. Splash Locations: Areas shown as splashproof shall have electrical installations as described for "outdoor locations."
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-5 CENTRAL PIPELINE PROJECT 1.7 CLEANUP
A. In addition to the requirements of "Cleanup" in Section 01700 - Project Closeout, all parts of the materials and equipment shall be thoroughly cleaned. Exposed parts shall be thoroughly clean of cement, plaster, and other materials. All oil and grease spots shall be removed with a nonflammable cleaning solvent. Such surfaces shall be carefully wiped and all cracks and corners scraped out. Paint touchup shall be applied to all scratches on panels and cabinets. Electrical cabinets or enclosures shall be vacuum cleaned before final acceptance.
B. During the progress of the Work, clean the premises and leave the premises and all portions of the site free of debris.
1.8 DEMOLITION AND RELATED WORK
A. The CONTRACTOR shall perform all electrical demolition work as indicated.
1. Electrical equipment and components, terminal and relay cabinets, MCCs, shall be returned to the OWNER in an orderly fashion to a designated location on the site. 2. Wire, conduit, junction boxes, fittings, supports and miscellaneous hardware removed a part of the demolition work shall not be reused and shall be returned to the OWNER for their salvage use. 3. Wires and/or conduits which need to be extended shall be terminated in a new terminal box with terminal strips. Terminal box shall be properly sized by the CONTRACTOR unless specified on drawings. Wires and terminals shall be properly identified before disconnection and after reconnection. 4. Wiring in conduits located in or under slabs shall be removed. The conduit shall be plugged level with the floor where practical. In other cases, the conduit shall be cut three inches below the finished floor and the area shall be resurfaced. 5. Openings in walls and platforms created by the removal of conduit or electrical equipment shall be patched with materials similar to those in surrounding work areas or as required to provide proper sealed conditions as reviewed and accepted by the ENGINEER. 6. Electrical demolition works shall be as shown on the Drawings or as required by the Specifications. 7. Exercise due care in the removal of the equipment made surplus by this project so as not to impair its resale value or reuse. The OWNER has the right to salvage any wire or other electrical equipment removed from the project. 8. Contractor shall be responsible for properly disposing of all electrical demolition materials, except those items to be salvaged to the OWNER as directed by the ENGINEER.
B. Installation of New Equipment in Existing Structures
1. Certain new equipment and devices' installation are required in existing structures. Under this phase of the Work the CONTRACTOR shall be required to remove existing equipment or devices, install new equipment as indicated, remove existing conductors from existing raceway, and pull new conductors in
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-6 CENTRAL PIPELINE PROJECT existing raceway, reconnect existing conductors or furnish and install new conduit and wires. 2. Visit the site before bidding and carefully examine existing installation so that its proposal will reflect all the Work necessary to provide a complete installation so that the resulting installation will function as required. Include in the bid price all costs of labor and materials necessary to complete installations.
C. Installation of Temporary Equipment
1. To facilitate continuous operation of existing equipment, provide temporary equipment indicated. Submit installation and connection details for review and acceptance. All costs associated with these temporary installations shall be part of the original Bid Documents, and without additional cost to the OWNER. 2. All cables, conduits, and fittings used in temporary connections shall not be reused to install permanent connections. Return the salvage items to the OWNER.
D. Plant Monitoring Power and Control Shutdowns
1. Continuance of plant operation during this demolition and expansion process is important. Therefore, carefully examine all Work to be done in, on, or adjacent to existing equipment. Work shall be scheduled, subject to OWNER’S approval, to minimize required plant shutdown time. Submit a written request, including sequence and duration of activities to be performed during plant shutdown. 2. Perform all switching and safety tagging required for plant shutdown or to isolate existing equipment. In no case shall the CONTRACTOR begin any Work in, on, or adjacent to existing equipment without written authorization.
E. Modifications to Existing Electrical Facilities
1. Provide all modifications or alterations to existing electrical facilities required to successfully install and integrate the new electrical equipment. All modifications to existing equipment, panels, or cabinets shall be made in a professional manner with all coatings repaired to match existing. The total costs for all modifications to existing electrical facilities required for a complete and operating system shall be included in the original bid amount and no additional payment for this Work shall be authorized. Extreme caution shall be exercised in digging trenches in order not to damage existing underground utilities. Cost of repairs of damages caused during construction shall be the CONTRACTOR's responsibility. 2. The CONTRACTOR shall be responsible for verifying all available existing circuit breakers in lighting panels for their intended use as required by the Drawings. It shall also be responsible for verifying the available space in substation switchboards to integrate new power circuit breakers. Expenses in time for all of this Work shall be included in the original bid amount.
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-7 CENTRAL PIPELINE PROJECT
PART 2 – PRODUCTS
2.1 GENERAL
A. All equipment and materials shall be new, shall be listed by UL, and shall bear the UL label, where UL requirements apply. All equipment and materials shall be the products of experienced and reputable manufacturers in the industry. Similar items in the project shall be products of the same manufacturer. All equipment and materials shall be of industrial grade and standard of construction; shall be of sturdy design and manufacture; and shall be capable of reliable, trouble-free service.
2.2 GROUNDING
A. General: All components of the grounding electrode system shall be manufactured in accordance with UL 467 and shall conform to the applicable requirements of National Electrical Code Article 250. B. Grounding cable shall be copper. Bare copper wire shall be annealed, No. 8 AWG minimum, if not called out in the Drawings.
C. Ground rods shall conform to ANSI/UL 467 and shall be ¾-inch diameter copper-clad steel, sectional type, joined by threaded copper alloy couplings.
1. Grounding connectors shall be high-strength copper alloy suitable for direct burial. 2. Wire connections shall be exothermic weld by Cadweld of Erico Products. a. Manufacturers of grounding materials shall be Copperweld, Blackburn, Burndy, or equal.
2.3 UNDERGROUND DUCTS AND MANHOLES
A. General: Where an underground distribution system is required, it shall be comprised of multiple runs of single bore nonmetallic ducts, with underground manholes and pullboxes. When nonmetallic ducts are required, they shall be rigid Schedule 40 PVC for concrete encasement.
1. Manholes and pullboxes shall be of precast concrete. Concrete construction shall be designed for traffic loading.
F. Covers shall be traffic type, except as shown otherwise. Manholes and pullbox covers designated as "HV" covers shall be identified as "High Voltage Electric," "P" shall be identified as "Secondary Electric," "C" as "Control" and "S" as "Signal." All covers shall be watertight after installation.
G. Manholes and pullboxes shall be equipped with pulling-in irons opposite and below each ductway entrance.
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-8 CENTRAL PIPELINE PROJECT H. Manholes shall have concrete covers with 30--inch diameters lids. All covers and lids shall be bolted to cast-in-place steel frames with corrosion resistant hardware. Frames shall be factory-primed; covers shall be cast-iron and shall have pick holes or lifting handles.
1. Manholes and pullboxes shall have cable supports so that each cable is supported at 3-foot intervals within the manhole or pullbox. Cable supports and racks shall be fastened with galvanized bolts and shall be fabricated of fiberglass or galvanized steel. Porcelain insulators for cable racks shall be provided. 2. Manholes and pullboxes shall be Brooks, Quikset, U.S. Precast, or equal.
I. The concrete envelope shall have a compression strength of 3,000 psi in accordance with the requirements of Section 03300 - Cast-in-Place Concrete.
2.4 RACEWAYS
A. General: Raceway shall be manufactured in accordance with UL and ANSI standards and shall bear UL label as applicable.
B. Galvanized Rigid Steel (GRS) Conduit
1. Rigid steel conduits and fittings shall be full weight, mild steel, hot-dip galvanized and zinc bichromate coated inside and outside after galvanizing. 2. Rigid steel conduit shall be manufactured in accordance with UL Standard No. 6 and ANSI 80-1. 3. Rigid steel conduit shall be manufactured by Triangle PWC, Republic Steel, or equal.
C. Rigid nonmetallic conduit shall be Schedule 40 PVC.
1. Nonmetallic conduits and fittings shall be UL listed, sunlight-resistant, and rated for use with 90 degrees C conductors. 2. Nonmetallic conduits and fittings shall be manufactured by Carlon, Condux, or equal.
D. Flexible metallic conduit shall be fabricated from galvanized interlocked steel strip. Liquid-tight flexible metallic conduit shall have an extruded PVC covering over the flexible steel conduit. For conduit sizes 3/4 inch through 1-1/4 inches, flexible conduits shall have continuous built in copper ground conductor. Flexible conduit shall be American Brass, Anaconda, Electroflex, or equal.
E. PVC-coated raceway system shall conform to Federal Specification WW-C-581E, ANSI C80.1, and to Underwriter's Laboratories specifications.
1. The zinc surfaces of the conduits and fittings shall remain intact and undisturbed on both the inside and the outside of the conduit through the preparation and application processing. 2. A PVC coating shall be bonded to the galvanized outer surface of the conduit. The bond between the PVC coating and the conduit surface shall be greater than the tensile strength of the plastic.
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-9 CENTRAL PIPELINE PROJECT 3. The thickness of the PVC coating shall be a minimum of 40 mils. a. A PVC jacketed coupling shall be furnished with each length of conduit. A PVC sleeve equal to the OD of the conduit shall extend 1-1/2 inches from each end of coupling. b. PVC-coated conduits shall be as manufactured by Robroy, Occidental (OCCAL), or equal.
2.5 WIRE AND CABLE
A. General: All conductors, including ground conductors, shall be copper. Insulation shall bear UL label and the manufacturer's trademark, type, voltage and temperature rating, and conductor size. Wire and cable shall be products of American, BICC/General, Rome Cable, Okonite, or equal.
B. Control Cables: All control cables shall be rated for 600 volts and shall meet the following requirements:
1. Control wires shall consist of No. 16 gage stranded copper conductors and shall be THWN rated for 90 degrees C at dry locations and 75 degrees C at wet locations. 2. Control wires at panels and cabinets shall be machine tool grade type MTW, UL approved, rated for 90 degrees C at dry locations.
C. Instrumentation Cables: Shielded instrumentation cables shall be rated at 300 volts and shall comply with the following requirements:
1. Individual shielded cable shall consist of twisted 2 or 3 No. 18 gage, stranded, color coded, tinned-coated copper in accordance with ASTM B 33 - Specification for Tinned Soft or Annealed Copper Wire for Electrical Purposes and B 8 - Specification for Concentric-Lay-Stranded Copper Conductors, Hard, Medium-Hard, and Soft. Color coding shall be black-clear, or black-red-clear. 2. Insulation thickness shall be 32 mils of polyethylene, insulated with 2.3 mils 100 percent aluminum foil/polyester shield and No. 18 stranded tinned copper drain wire, all under a 32 mil PVC jacket. The shield shall be continuous and shall be grounded only at the receiving end, or as indicated. 3. Multi-individual shielded pair or triad instrumentation cable shall consist of individual shielded and twisted pair copper conductors with an ethylene-propylene insulation, and No. 18 AWG tinned stranded copper drain wire, an overall aluminum mylar shield and an overall chloro-sulfonated polyethylene compound jacket. The cables shall be suitable for cable tray installation and shall be flame retardant.
D. Building Wire and Cable: Building wires and cables shall be rated at 600 volts and shall meet the following requirements:
1. Building wire shall be single conductor copper cable listed by UL as Type THWN rated 75 degrees C in wet locations and THHN rated 90 degrees C in dry locations. 2. Building wire; all conductors shall be stranded. 3. No wire smaller than No. 12 AWG shall be used unless specifically indicated.
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-10 CENTRAL PIPELINE PROJECT E. Cable Terminations: Cable terminations shall be in accordance with the following:
1. Compression connectors shall be Burndy "Hi Lug", Thomas & Betts "Shure Stake", or equal. Threaded connectors shall be split bolt type of high strength copper alloy. 2. Spring connectors (wire nuts) shall be 3M "Scotch Lok," "Ideal Wing Nuts", or equal. 3. Preinsulated fork tongue lugs shall be "Thomas & Betts" RC Series, Burndy, or equal. 4. General purpose insulating tape shall be Scotch No. 33, Plymouth "Slip-knot", or equal. High temperature tape shall be polyvinyl by Plymouth, 3M, or equal. 5. Epoxy resin splicing kits shall be 3M Scotchcoat 82 Series, Burndy Hy Seal, or equal. 6. Stress cone material for makeup of medium voltage shielded cable shall be by 3M- No substitutions. 7. Motor load termination kits shall be 3M.
2.6 PULL AND JUNCTION BOXES
A. Outlet, switch, pull and junction boxes for flush-mounting in general purpose locations shall be one-piece, galvanized, pressed steel. Ceiling boxes for flush-mounting in concrete shall be galvanized, pressed steel.
B. Outlet, switch, pull and junction boxes where surface mounted in exposed locations shall be cast ferrous boxes with mounting lugs, zinc or cadmium plating, and enamel finish. Surface mounted boxes in concealed locations may be pressed steel.
C. Control station, pull and junction boxes, including covers, for installation in corrosive locations shall meet the NEMA 4X requirements and shall be stainless steel or fiber glass-reinforced polyester and shall be furnished with mounting lugs.
D. All cast boxes and pressed steel boxes for flush mounting in concrete shall be fitted with cast, malleable box covers and gaskets. Covers for pressed steel boxes shall be one- piece pressed steel, cadmium plated, except that boxes for installation in plastered areas and finished rooms shall be stainless steel over plaster rings. Stainless steel plates shall be Sierra S-line, Hubbell, or equal. Cast boxes shall be as manufactured by Crouse-Hinds, Appleton, or equal.
2.7 CONDUIT FITTINGS
A. General: Fittings shall comply with the same requirements as the raceway with which they will be used. Fittings for use with rigid steel conduit, shall be cast or malleable ferrous metal. Such fittings larger than one inch shall be "mogul size." Fittings shall be of the gland ring compression type. Covers of fittings, unless in "dry" locations, shall be closed with gaskets. Surface-mounted cast fittings, housing wiring devices in outdoor and damp locations, shall have mounting lugs.
B. Insulated bushings shall be molded plastic or malleable iron with insulating ring, similar to O-Z Type A and B, equivalent types by Thomas & Betts, Steel City, Appleton, O-Z/Gedney, or equal.
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-11 CENTRAL PIPELINE PROJECT C. Insulated grounding bushings shall be malleable iron with insulating ring and with ground lug, - by T & B, - no substitutions.
D. Crouse Hinds UNF or UNY unions shall be used at all points of union between ends of rigid steel conduits which cannot be coupled. Running threads and threadless couplings shall not be used.
E. Liquid-tight fittings shall be - manufactured by T & B, no substitutions.
F. Hubs for threaded attachment of steel conduit to sheet metal enclosures shall be similar to Appleton Type HUB, equivalent types such as manufactured by T & B, Myers Scrutite, or equal.
G. Transition fittings to mate steel to PVC conduit, and PVC access fitting, shall be as furnished or recommended by the manufacturer of the PVC conduit.
H. Conduit sealant shall be Chico, or equal.
I. Expansion fittings shall be installed wherever a raceway crosses a structural expansion joint. Such fittings shall be expansion and deflection type and shall accommodate lateral and transverse movement. Fittings shall be O-Z/Gedney Type "DX," Crouse Hinds "XD," or equal. These fittings are required in metallic and nonmetallic raceway installations. When the installation is in a nonmetallic run, a 3-foot length of rigid conduit shall be used to connect the nonmetallic conduit to the fitting.
2.8 WIRING DEVICES
A. All wiring devices shall be a product of a single manufacturer and shall conform to applicable NEMA Standards and be UL listed. Devices shall be as manufactured by Hubbell, Sierra, Pass & Seymour, or equal. General purpose duplex receptacles and toggle switch handles shall be white. Special purpose receptacles shall have a body color as shown. Receptacles and switches shall conform to Federal Specifications W-C-596E and W-S-896E, respectively.
1. Receptacles a. General purpose duplex receptacles shall be grounding type, 125-volt, ac, 20- amperes, backwired NEMA Configuration 5-20R, such as Hubbell 5362, or equal.
B. Convenience receptacles for installation in outdoor and corrosive areas shall be NEMA 5-20R configured and shall have stainless steel or nickel plated parts and plastic parts of Melanine.
1. Receptacles at outdoor locations shall be UL-approved for weatherproof locations with plug inserted. These shall be Crouse-Hinds, Hubbell, Pin and Sleeve Series, or equal. 2. Receptacles at damp or dry locations shall be Crouse-Hinds DS 23G, Pyle National N-1, or equal. 3. Receptacles at corrosive locations shall be Hubbell 52CM62 15 ampere, 53CM62 20 ampere, or equal.
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-12 CENTRAL PIPELINE PROJECT C. Ground fault interrupter (GFI) receptacles shall be NEMA 5-20R configured and shall mount in a standard outlet box. Units shall trip at 5 milliamperes of ground current and shall comply with NEMA WD-1-1.10 and UL 943. GFI receptacles shall be capable of individual as well as "downstream" operation. GFI receptacles shall be Hubbell GF 5362, or equal.
1. Switches a. Switches at outdoor locations shall be Crouse-Hinds DS 128, Mackworth Rees Style 3845, Joy Flexitite, or equal. b. Switches at damp locations shall be Mackworth Rees Style 3496, Joy Flexitite, or equal. c. Switches at dry locations shall be Crouse-Hinds DS 32G, Pyle National SCT-10k, or equal.
D. Toggle switches shall be suitable for back wiring and shall conform to the following table, or equal:
Bryant No. Hubbell No. Bryant No. Single Pole 4901 (white) 1221W (white) 4901W (white) Three Way 4903 1223W 4903W Momentary 4821 1556W 4821W Four Way 1224W
2.9 CABINETS AND ENCLOSURES
A. General: All electrical cabinets and enclosures housing control relays and terminal blocks shall be manufactured in accordance with NEMA Publications 250, UL Standards 50 and 508.
1. Relay or control, and terminal cabinets or outdoor cabinets shall be NEMA 4 enclosures. Sizes shown on the Drawings are minimum. Provide sufficient terminal blocks to terminate 25 percent more conductors than are shown. Interiors of cabinets shall be finished white including internal back mounting plate. 2. Floor standing NEMA 12 construction shall have three-point latching mechanism operated by oiltight key-locking handle, and shall have gasketed overlapping doors. Steel construction shall be 12-gauge; construction for wall-mounted type shall be 14-gauge steel. Exterior finish shall be ANSI 61 light gray, or equal.
B. Wiring of terminal cabinets, control or relay cabinets shall be accomplished with stranded copper conductor rated for 600-volts and UL listed as Type MTW. Wires for annunciator and indication circuits shall be No. 16 AWG. All others shall be No. 14 AWG. Color coding shall be as specified elsewhere in this Section. Incoming wires to terminal or relay cabinets shall be terminated on a master set of terminal blocks. All wiring from the master terminals to internal components shall be factory-installed and shall be contained in plastic wireways having removable covers. Wiring to door- mounted devices shall be extra flexible and anchored to doors using wire anchors cemented in place. Exposed terminals of door-mounted devices shall be guarded to prevent accidental personnel contact with energized terminals.
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-13 CENTRAL PIPELINE PROJECT C. All terminal block requirements shall be as manufactured by Entrelec with cage clamp, Phoenix, or equal.
D. Engraving shall be as shown or as directed by the ENGINEER. Characters shall be uniform block style not smaller than 1/8-inch. Nameplates shall be secured using cadmium plated steel or other corrosion resistant screws. Adhesive alone is not acceptable.
E. Each relay or control and terminal cabinets shall be completed, assembled, wired, and tested at the factory. Test shall be in accordance with the latest UL and NEMA Standards. All cabinets shall bear UL label, as applicable.
2.10 DISCONNECT SWITCHES
A. Unfused and fused disconnect switches shall be externally operated with quick- make/quick-break mechanisms. The handle shall be interlocked with the switch cover by means of a defeatable interlock device. The switch shall be padlockable in the "off" position. Switches shall have nameplates stating manufacturer, rating, and catalog number. Heavy-duty switches shall have arc suppressors, pin hinges, and shall be horsepower rated at 600-volts. All switches rated at 100 amperes or larger shall have auxiliary contact for remote status indication. Heavy-duty switches shall be provided for all motor circuits above 3 horsepower. In smaller motor circuits switches shall be general duty.
B. Switch rating shall match the horsepower requirements of the load at the particular voltage if not otherwise shown.
C. Switch enclosure shall be NEMA 1 and shall be as manufactured by Square D, Cutler- Hammer, or equal.
2.11 ELECTRICAL IDENTIFICATION
A. Nameplates: Nameplates shall be fabricated from white-letter, black-face laminated plastic engraving stock, Formica type ES-1, or equal. Each shall be fastened securely, using fasteners of brass, cadmium plated steel, or stainless steel, screwed into inserts or tapped holes, as required. Engraved characters shall be block style of adequate size to be read easily at a distance of 6 feet with no characters smaller than 1/8-inch high.
B. Conductor and Equipment Identification: Conductor and equipment identification devices shall be either imprinted plastic-coated cloth marking devices such as manufactured by Brady, Thomas & Betts, or equal, or shall be heat-shrink plastic tubing, imprinted split-sleeve markers cemented in place, or equal.
C. Identification Tape: Identification tape for protection of buried electrical installation shall be a 6-inch wide red polyethylene tape imprinted "CAUTION – ELECTRIC UTILITIES BELOW."
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-14 CENTRAL PIPELINE PROJECT 2.12 LIGHTING AND POWER PANELBOARDS
A. General: Panelboards shall be dead front factory assembled. Panelboards shall comply with NEMA PB-1 as well as the provisions of UL 50 and 67. Panelboards used for service equipment shall be UL labeled for such use. Lighting panelboards shall be rated for 120/208-volt 3-phase operation or 120/240-volt for single phase operation as shown. Power panelboards shall be rated for 600 volts, 3-phase operation.
1. Interiors shall have solderless, anti-turn connectors and shall be constructed so that branch circuit breaker can be replaced without disturbing adjacent units or resorting to field drilling and tapping. Bus bars and connecting drops shall be copper. Neutral bar shall be full-sized and shall have one terminal screw for each branch circuit; main bus bar shall be full-sized for entire length. Spaces shown shall have cross connections for the maximum sized device that can be fitted.
2. Panelboard box shall be galvanized code grade steel with knockouts, and shall have removable end walls. All boxes or panelboard enclosures shall have gray baked enamel finish. 3. All circuit breakers shall be bolt-in type.
B. Lighting Panelboards
1. Cabinets for building panels shall be 20-inch wide minimum, with 4-inch minimum side gutters and 5-inch minimum top and bottom gutters. Panelboard trim shall be the same size as cabinet on surface-mounted panels and 3/4-inch larger all around than cabinet of flush-mounted panels. Bus bars shall be copper. Doors in trim shall have typed circuit directory and pocket with protective clear plastic sheet. All trim and cabinets of surface-mounted panels in general purpose areas shall be phosphate treated, primed and finished with baked enamel, panels of flush mounted panels shall be finished to match surrounding wall color. 2. The number of circuit breakers and the ampere ratings shall be in accordance with panel schedules. Main circuit breaker or main lugs only shall be provided as indicated. The panelboard circuit breakers shall be group mounted and shall be molded case with 3- or 2-pole main breakers as required and branch circuit breakers with 18,000 AIC. 3. Provide control enclosures under common panel trim. All panelboard doors shall be keyed alike.
2.13 PROCESS CONTROL DEVICES
A. Liquid Level Control: Liquid level controls shall be as indicated. Level settings shall be determined by Design ENGINEER and received from the ENGINEER.
1. High level flood switches shall be as shown on the drawings.
2.14 CONTROL STATIONS
A. Control stations shall comply with NEMA Standards ICS2-216. All control stations shall be industrial type, heavy duty, oil-tight, with legend plates.
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-15 CENTRAL PIPELINE PROJECT B. Control stations shall be as follows:
1. Pushbutton Switch: Pushbutton switches shall be momentary type with round or square button plate. All emergency-stop pushbuttons shall have red button plates. Lock-out stop shall be momentary pushbutton with locking mechanism. 2. Selector Switches: Selector switches shall be rated 10 amperes at 600 volts and shall be rotary type with number of position and poles as indicated. 3. Indicating Lights: Pilot lights shall be LED type and with plastic color caps: green color for running, yellow for ready, white for power status, and red for failure status. 4. Control station enclosures shall be NEMA 4X in corrosive, below grade, or wet areas.
C. Manufacturers shall be Square D with Class 9001, or equal.
PART 3 – EXECUTION
3.1 GROUNDING
A. General: Grounding cable shall be sized in accordance with code requirements when sizes are not indicated on the Drawings.
B. Equipment Ground: Ground continuity throughout the facility shall be maintained by installing a grounding conductor in all raceways.
1. Metallic raceway shall be installed with double lock nuts or hubs at enclosures. Nonmetallic raceway containing dc conductors operating at more than 50 volts to ground, or any ac conductors, shall contain a copper-grounding conductor insulated green. Such conductor shall be bonded to terminal and intermediate metallic enclosures. 2. Metal equipment platforms which support any electrical equipment shall be bonded to the nearest ground bus or to the nearest switchgear ground bus. This grounding requirement is in addition to the raceway grounding required in the preceding paragraph herein.
C. Grounding Electrode System: Install the grounding electrode system with all required components in accordance with National Electrical Code Article 250.
1. Connection to ground electrodes and ground conductors shall be exothermic welded where concealed and shall be bolted pressure type where exposed. Bolted connectors shall be assembled wrench-tight. 2. Insulated grounding bushings shall be employed for all grounding connections to steel conduits in switchboards, in motor control centers, in pullboxes, and elsewhere where conduits do not terminate at a hub or a sheet metal enclosure. Where insulated bushings are required, they shall be installed in addition to double lock- nuts. 3. Copper bonding jumpers shall be used to obtain a continuous metallic ground.
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-16 CENTRAL PIPELINE PROJECT
D. Shield Grounding
1. Shielded power cable shall have its shield grounded at each termination in a manner recommended by the cable manufacturer. 2. Shielded instrumentation cable shall be grounded at one end only; this shall be at the RTU or otherwise at the "receiving" end of the signal carried by the cable, unless shop drawings indicate that the shield shall be grounded at both ends. 3. Termination of each shield drain wire shall be on its own terminal screw. All of these terminal screws in one rack shall be jumpered with No. 16 solid tinned bare copper wire; connection to ground shall be accomplished with a No. 12 green insulated conductor to the main ground bus.
3.2 UNDERGROUND DUCTS AND MANHOLES
A. The underground duct bank shall be installed in accordance with the criteria below:
1. Duct shall be assembled using high impact nonmetallic spacers and saddles to provide conduits with vertical and horizontal separation. Plastic spacers shall be set every 5 feet. 2. The duct shall be laid on a grade line of at least 4 inches per 100 feet, sloping towards pullboxes or manholes. Duct shall be installed and pullbox and manhole depths adjusted so that the top of the duct is a minimum of 24 inches below grade. 3. Changes in direction of the duct envelope by more than 10 degrees horizontally or vertically shall be accomplished using bends with a minimum radius 24 times the duct diameter. 4. Couplings shall be staggered at least 6 inches vertically. Bottom of trench shall be of select backfill or sand. The duct array shall be anchored every 4 feet to prevent movement during placement of backfill. 5. Each bore of the completed duct bank shall be cleaned by drawing through it a standard flexible mandrel one foot long and 1/4-inch smaller than the nominal size of the duct through which the mandrel will be drawn. After passing of the mandrel, draw a wire brush and swab through. a. A raceway, in the duct envelope, which does not require conductors, shall have a 1/8-inch polypropylene pull cord installed throughout the entire length of the raceway.
B. Duct entrances shall be grouted smooth; duct for primary and secondary cables shall be terminated with flush end bells. Sections of pre-fabricated manholes and pullboxes shall be assembled with waterproof mastic and shall be set on a 6-inch bed of gravel as recommended by the manufacturer or as required by field conditions.
C. Duct bank markers shall be installed every 200 feet along run of duct bank, at changes in horizontal direction of duct bank, and at ends of duct bank. Concrete markers, 6 by 6 inches square and one-foot long, shall be set 2 inches above finish grade. The letter "D" and arrow set in the concrete shall be facing in the direction of the duct alignment.
D. Duct bank penetration through walls of manholes or pullboxes, and on building walls below grade shall be watertight.
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-17 CENTRAL PIPELINE PROJECT E. Trenches containing duct banks shall be filled with select backfill with no large rocks which could damage the duct.
F. Concrete encased duct bank shall terminate at building foundations. When duct enters the building on a concrete slab on grade, duct shall not be encased, but shall transition to rigid steel PVC-coated conduits on all stub-ups.
3.3 RACEWAYS
A. General: Raceways shall be installed as indicated, however, conduit routings shown are diagrammatic. Raceway systems shall be electrically and mechanically complete before conductors are installed. Bends and offsets shall be smooth and symmetrical, and shall be accomplished with tools designed for the purpose intended. Bends in metallic conduit shall be accomplished by field bending or by the use of factory elbows. All installations shall be in accordance with the latest edition of the National Electrical Code.
B. Raceways shall be installed in accordance with the following schedule:
1. Low Voltage Raceway (control and power): a. Rigid Schedule 40 PVC shall be used for concrete encased duct in earth. b. Galvanized rigid steel (GRS) shall be used on exposed installations in general purpose areas. c. Galvanized rigid steel or PVC shall be used for conduits embedded in concrete slab on grade and above grade. d. Schedule 40 PVC shall be used for fiber optic data hi-way system concrete encased on grade. e. Galvanized rigid steel shall be used in exposed installations in outdoor areas. f. Galvanized rigid steel or EMT in concealed locations above grade. g. All exposed conduit in room FB01 of Fluoride Building shall be PVC coated RGS and shall be supported with fiberglass strut. h. All exposed conduit in rooms FB02, FB03, and FB04 of Fluoride Building shall be RGS and shall be supported with zinc coated strut. 2. Exposed Raceways a. Conduits shall be rigidly supported with clamps, hangers, and Unistrut channels. b. Intervals between supports shall be in accordance with the National Electrical Code. 3. All underground elbows shall be GRS (coated or wrapped).
C. Conduit Terminations
1. Empty conduit terminations not in manholes or pullboxes shall be plugged. Exposed reaceway shall be installed perpendicular or parallel to buildings except where otherwise indicated. Conduit shall be terminated with flush couplings at exposed concrete surfaces. Conduit stubbed up for floor-standing equipment shall be placed in accordance with approved shop drawings. Metallic raceways installed below-grade or in outdoor locations and in concrete shall be made up with a conductive waterproof compound applied to threaded joints. Compound shall be Zinc Clads Primer Coatings No B69A45, HTL-4 by Crouse-Hinds, Kopr Shield by Thomas & Betts, or equal.
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-18 CENTRAL PIPELINE PROJECT 2. Both rigid and flexible conduit shall be sealed against water at each entrance to enclosures. Unless indicated otherwise, rigid and flexible conduit shall enter panels through the top, shall continue down from the top to the bottom, and shall turn upward at the bottom.
D. Conduit Installations
1. Conduit may be cast integral with horizontal and vertical concrete slabs, providing one-inch clearance is maintained between conduit surface and concrete surface. If said clearance cannot be maintained, the conduit shall be installed exposed below elevated slabs; provided, that in the case of slabs on grade, conduit shall be installed below the slab and shall be encased with a minimum cover of 3 inches of concrete. Maximum size of conduit that can be cast in slab above grade shall be 3 inches, in slab on grade shall be 1-1/2 inches. 2. Nonmetallic conduit may be cast integral with horizontal slabs with placement criteria stated above. Non-metallic conduit may be run beneath structures or slabs on grade, without concrete encasement. In these instances conduit shall be placed at least 12 inches below the bottom of the structure or slab. Nonmetallic conduit may be buried 24 inches minimum below grade, with a 3-inch concrete cover, in open areas or where otherwise not protected by concrete slab or structures. Top of concrete cover shall be colored red. Nonmetallic conduit shall be permitted only as required by the Specifications and in concealed locations as described above. 3. Where a run of concealed PVC conduit becomes exposed, a transition to rigid steel conduit is required. Such transition shall be accomplished by means of a factory elbow or a minimum 3-foot length of rigid steel conduit, either terminating at the exposed concrete surface with a flush coupling. Piercing of concrete walls by nonmetallic runs shall be accomplished by means of a short steel nipple terminating with flush couplings. 4. Flexible liquid-tight conduit shall be used for the connection of equipment such as motors, transformers, instruments, valves, or pressure switches subject to vibration or movement during normal operation or servicing. Flexible conduit may be used in lengths required for the connection of recessed lighting fixtures; otherwise the maximum length of flexible conduit shall be 18 inches. 5. Connections shall be made using flexible liquid-tight conduit. Equipment subject to vibration or movement which is normally provided with wiring leads, such as solenoid valves, shall be installed with a cast junction box for the make-up of connections. Flexible conduits shall be as manufactured by American Brass, Cablec, Electroflex, or equal. 6. Conduit penetrations on walls, concrete structures, pull boxes, and equipment cabinets shall be performed in accordance with the following: a. Seal all raceways entering structures at the first box or outlet with conduit sealant to prevent the entrance into the structure of gases, liquids, or rodents. b. Dry pack with nonshrink grout around raceways that penetrate concrete walls, floors, or ceilings aboveground, or use one of the methods indicated for underground penetrations. c. Where an underground conduit enters a structure through a concrete roof or a membrane waterproofed wall or floor, provide an acceptable, malleable iron, watertight, entrance sealing device. When there is no raceway concrete encasement, provide such device having a gland type sealing assembly at each end with pressure bushings which may be tightened at any time. When
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-19 CENTRAL PIPELINE PROJECT there is raceway concrete encasement indicated, provide such a device with a gland type sealing assembly on the accessible side. Securely anchor all such devices into the masonry construction with one or more integral flanges. Secure membrane waterproofing to such devices in a permanently watertight manner. d. Where an underground raceway without concrete encasement enters a structure through a nonwaterproofed wall or floor, install a sleeve made of Schedule 40 galvanized pipe. Fill the space between the conduit and sleeve with a suitable plastic expandable compound, or an oakum and lead joint, on each side of the wall or floor in such a manner as to prevent entrance of moisture. A watertight entrance sealing device may be used in lieu of the sleeve. 7. All underground GRS conduit shall be PVC coated or taped.
3.4 WIRES AND CABLES
A. General: Conductors shall not be pulled into raceway until:
1. Raceway system has been inspected and accepted by the ENGINEER. 2. Plastering and concrete have been completed in affected areas. 3. Raceway system has been freed of moisture and debris.
B. Wire and Cables
1. Conductors of No. 1 size and smaller shall be hand pulled. Larger conductors may be installed using power winches. Pulling tensions on the cables shall be within the limits recommended by the cable manufacturer. Wire pulling lubricant, where needed, shall be UL approved. 2. Wire in panels, cabinets, and gutters shall be neatly grouped using nylon tie straps, and shall be fanned out to terminals.
C. Splices and Terminations
1. The CONTRACTOR shall provide, install, and terminate the conductors required for power and controls to electrical equipment instrumentation terminal cabinets, control and instrumentation equipment except where indicated elsewhere. There shall be no cable splices in underground manhole or pullboxes. If splices are necessary, the cables shall be brought aboveground and terminated in a NEMA 4X, stainless steel terminal or splice cabinet on a concrete pad. 2. Two- and three-conductor shielded cables installed in conduit runs which exceed 2,000 feet may be spliced in pullboxes. These cable runs shall have only one splice per conductor. 3. Control conductors shall be spliced or terminated only at the locations indicated and only on terminal strips or terminal lugs of vendor furnished equipment. For the purposes of the various Sections of Division 16 of the Specifications, "control conductors" are defined as conductors operating at 120 volts or less in circuits that indicate equipment status or that control the electric energy delivered to a power consuming device. 4. All 120/208-volt and 480-volt branch circuit conductors may be spliced in suitable fittings at locations determined by the CONTRACTOR.
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-20 CENTRAL PIPELINE PROJECT 5. Stranded conductors shall be terminated directly on equipment box lugs making sure that all conductor strands are confined within lug. Use forked-tongue lugs where equipment box lugs have not been provided. 6. Splices in 600-volt wire which are not pre-insulated shall be insulated with three layers of tape each half lapped except that splices in below grade pull boxes or in any box subject to flooding shall be made watertight using an epoxy resin splicing kit. 7. Splices to motor leads in motor terminal boxes shall be wrapped with mastic material to form a mold and then shall be taped with a minimum of 2 layers of varnished cambric tape overtaped with a minimum of 2 layers of high temperature tape. Provide 3M motor lead termination kits. 8. Shielded power cable shall be terminated with pre-assembled stress cones in a manner approved by the cable manufacturer. Submit the proposed termination procedure as described for shop drawings. a. Control devices, such as solenoid operated valves, that are normally supplied with conductor pigtails, shall be terminated as described for control conductors.
D. Cable Assembly and Testing: Cable assembly and testing shall comply with applicable requirements ICEA Publication No. S-68-516 and other relevant ICEA publications. Factory test results shall be submitted in accordance with Section 01300 - Contractor Submittals, prior to shipment of cable. The following tests shall be the minimum requirements:
1. Insulation resistance shall be obtained and shall not be less than the value recommended by ICEA. 2. All cables rated at 600 volts shall be tested for insulation resistance between phases and from each Phase to a ground using a megohmeter. 3. All field testing mentioned above shall be done after cables are installed in the raceways. 4. Field tests shall be performed by certified test organization acceptable to the ENGINEER. Test results shall be submitted for review and acceptance. 5. Cables failing in the said tests shall be replaced with a new cable or repaired. Such kind of repair methods shall be as recommended by the cable manufacturer and shall be performed by persons certified by the industry.
E. Continuity Test: All control and instrumentation cables shall be tested for continuity, polarity, undesirable ground, and origination. Such tests shall be performed prior to placing all cables in service.
3.5 PULL AND JUNCTION BOXES
A. Pull and junction boxes shall be sized in accordance with the requirements of the National Electrical Code or as shown on drawings.
B. Outlet boxes shall be used as junction boxes wherever possible. Where separate pullboxes are required, they shall have screw covers.
C. Pullboxes shall be installed when conduit run contains more than three 90-degree bends and runs exceed 200 feet.
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-21 CENTRAL PIPELINE PROJECT 3.6 CABINETS AND ENCLOSURES
A. Cabinets shall be set plumb at an elevation that will cause the maximum circuit breaker height to be less than 5 ft 6 inches. Top edge of trim of adjacent panels shall be at the same height. Panels which are indicated as flush mounted shall be set so cabinet is flushed and serves as a "ground" for plaster application.
B. All factory wire connections shall be made at shipping splits, and all field wiring and grounding connections shall be made after the assemblies are anchored.
3.7 CONCRETE HOUSEKEEPING
A. Concrete housekeeping pads shall be provided for all floor standing electrical equipment. Housekeeping pads for all equipment, including future units, shall be 2 inches above surrounding finished floor or grade and 2 inches larger in both dimensions than the supported equipment, unless otherwise indicated.
B. Concrete housekeeping curb shall be provided for all conduit stub-up in indoor and outdoor locations, not concealed by equipment enclosures. Such curb shall be 3 inches above finished floor or grade. 3.8 EQUIPMENT ANCHORING
A. Freestanding or wall-hung equipment shall be anchored in place by methods that will meet seismic requirement in the area where project is located. Wall-mounted panels that weigh more than 500 pounds or which are within 18 inches of the floor shall be provided with fabricated steel support pedestal(s). Pedestals shall be of welded steel angle sections. If the supported equipment is a panel or cabinet and enclosed with removable side plates, it shall match supported equipment in physical appearance and dimensions. Transformers hung from 4-inch stud walls and weighing more than 300 pounds, shall have auxiliary floor supports.
B. Leveling channels anchored to the concrete pad shall be provided for all switchgear and pad-mounted transformer installations. Area between the channels shall be grouted perfectly flat.
C. Anchoring methods and leveling criteria specified in the printed recommendations of the equipment manufacturers are a part of the Work of this Contract. Such recommendations shall be submitted as required for shop drawings in Section 01300 - Contractor Submittals.
3.9 CABLE AND EQUIPMENT IDENTIFICATION
A. General: The completed electrical installation shall be provided with adequate identification to facilitate proper control of circuits and equipment and to reduce maintenance effort.
B. Cable: Assign each control and instrumentation wire and cable a unique identification number. Said numbers shall be assigned to all conductors having common terminals and shall be shown on all shop drawings. Identification numbers shall appear within 3
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-22 CENTRAL PIPELINE PROJECT inches of conductor terminals. "Control" shall be defined as any conductor used for alarm, annunciator, or signal purposes:
1. Multiconductor cable shall be assigned a number which shall be attached to the cable at intermediate pull boxes and at stub-up locations beneath free-standing equipment. It is expected that the cable number shall form a part of the individual wire number. All individual control conductors and instrumentation cable shall be identified at pull points as described above. The instrumentation cable numbers shall incorporate the loop numbers indicated on the Drawings. 2. All 120/208-volt system feeder cables and branch circuit conductors shall be color coded as follows: Phase 1-black, Phase 2-red, Phase 3-blue, and Neutral-white. The 480/277-volt system conductors shall be color coded as follows: Phase A- brown, Phase B-orange, Phase C-yellow, and Neutral-gray. Color-coding tape shall be used where colored insulation is not available. Branch circuit switch shall be yellow. Insulated ground wire shall be green, and neutral shall be gray. Color coding and phasing shall be consistent throughout the site, but bars at panelboards, switchboards, and motor control centers shall be connected Phase 1-2-3, top to bottom, or left to right, facing the front of the equipment. 3. General purpose ac control cables shall be pink. General purpose dc control cables shall be blue. 4. All spare cables shall be terminated on terminal screws and shall be identified with a unique number as well as with destination. 5. Terminal strips shall be identified by imprinted, varnished, marker strips attached under the terminal strip.
C. Equipment: Equipment and devices shall be identified as follows:
1. Nameplates shall be provided for all panelboards, panels, starters, switches, and pushbutton stations. In addition to the name plates shown, control devices shall be equipped with standard collar-type legend plates. 2. Control devices within enclosures shall be identified similar to the paragraph above. 3. Three-phase receptacles shall be consistent with respect to phase connection of receptacle terminals. Errors in phasing shall be corrected at the bus, not at the receptacle. 4. Toggle switches which control loads out of sight of switch, and all multiswitch locations of more than 2 switches, shall have suitable inscribed finish plates. 5. Empty conduits shall be tagged at both ends to indicate the destination at the far end. Where it is not possible to tag the conduit, destination shall be identified by marking an adjacent surface. 6. Provide typewritten circuit directories for panelboards; circuit directory shall accurately reflect the outlets connected to each circuit. 7. Install identification tape directly above buried unprotected raceway; install tape 8 inches belowgrade and parallel with raceway to be protected. Identification tape is required for all buried raceway not under buildings or equipment pads except identification tape is not required for protection of street lighting raceway.
- END OF SECTION -
BC&A ELECTRICAL GENERAL PROVISIONS JVWCD PAGE 16050-23 CENTRAL PIPELINE PROJECT
SECTION 16222 MOTORS 250HP AND LESS
PART 1 – GENERAL
1.1 THE REQUIREMENT
A. General: The Contractor shall provide electric motors, accessories, and appurtenances, complete and operable, in accordance with the Contract Documents.
B. The provisions of this Section apply to electric motors 250 hp and less.
1.2 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS
A. American Bearing Manufacturers Association (ABMA):
1. ABMA 9 – Load Ratings and Fatigue Life for Ball Bearings. 2. ABMA 11 – Load Ratings and Fatigue Life for Roller Bearings.
B. Institute of Electrical and Electronic Engineers (IEEE):
1. IEEE 43 – Recommended Practice for Testing Insulation Resistance of Rotating Machinery. 2. IEEE 112 – Standard Test procedure for Polyphase Induction Motors and Generators. 3. IEEE 114 – Standard Test procedure for Single-Phase Induction Motors. 4. IEEE 303 – Recommended Practice for Auxiliary Devices for Motors in Class 1, Groups A, B, C, and D, Division 2 Locations. 5. IEEE 841 – Standard for Petroleum and Chemical Industry – Severe Duty totally Enclosed Fan-Cooled (TEFC) Squirrel Cage Induction Motors – up to and including 500hp. 6. IEEE 1349 – Guide for the Application of Electric Motors in Class I, Division 2 Hazardous (Classified) Locations.
C. National Electrical Manufacturers’ Association (NEMA):
1. MG-1 – Motors and Generators. 2. MG-1 – Safety Standard for Construction and Guide for Selection, Installation, and Use of Electric Motors and Generators.
D. Underwriters Laboratories Inc. (UL):
1. UL 674 – Electric Motors and Generators for use in Division 1 Hazardous (Classified) Locations.
BC&A MOTORS 250HP AND LESS JVWCD PAGE 16222-1 CENTRAL PIPELINE PROJECT
1.3 CONTRACTOR SUBMITTALS
A. Complete motor data shall be submitted with the driven machinery shop drawings. Motor data shall include:
1. Machine name and specification number of driven machine. 2. Motor manufacturer. 3. Motor type or model and dimension drawing. Include motor weight. 4. Nominal horsepower. 5. NEMA design. 6. Enclosure. 7. Frame size. 8. Winding insulation class and temperature rise class. 9. Voltage, phase and frequency ratings. 10. Service factor. 11. Full load current at rated horsepower for application voltage. 12. Full load speed. 13. Guaranteed minimum full load efficiency. Also provide nominal efficiencies at 1/2 and 3/4 load. 14. Type of thermal protection or overtemperature protection, if included. 15. Wiring diagram for devices such as motor leak detection, temperature, or zero speed switches, as applicable. 16. Bearing data. Include recommended lubricants for relubricatable type bearings. 17. If utilized with a variable frequency controller, verify motor is inverter duty type. Include minimum speed at which motor may be operated for the driven machinery. 18. Power factor at 1/2, 3/4 and full load. 19. Recommended size for power factor correction capacitors to improve power factor to 0.95 (lagging) when operated at full load.
B. If water cooling is required for motor thrust bearings, the shop drawing submittals shall indicate this requirement.
1.4 PROJECT CONDITIONS
A. Environmental Limitations: Rate equipment for continuous operation, capable of providing full motor load, under the following conditions unless otherwise indicated:
1. Ambient Temperature: Not less than minus 22 deg F and not exceeding 104 deg F. 2. Altitude: Not exceeding 4500 feet. 3. Humidity: Equal to or less than 95 percent (noncondensing).
1.5 DELIVERY, STORAGE, AND HANDLING
A. Storage and handling of motors shall be in accordance with manufacturer’s recommendations. Preferred storage is indoors in clean, dry space with uniform temperature to prevent condensation. Protect motors from exposure to dirt, fumes, water, corrosive substances, and physical damage.
BC&A MOTORS 250HP AND LESS JVWCD PAGE 16222-2 CENTRAL PIPELINE PROJECT 1.6 QUALITY ASSURANCE
A. All motors shall be UL listed and labeled.
PART 2 – PRODUCTS
2.1 MANUFACTURERS
A. One of the following or equal: 1. Emerson, US Motors. 2. General Electric. 3. Reliance. 4. Toshiba. 5. Baldor.
2.2 GENERAL REQUIREMENTS
A. Electric motors driving identical machines shall be identical.
B. Maximum motor loading shall in all cases be equal to nameplate horsepower rating or less, exclusive of service factor and as verified with the approved submittal data of the driven machinery.
1. Minimum Motor Horsepower: All motors shall be sized to carry continuously all loads which may be imposed through their full range of operation. The motor horsepower shall be not less than the estimated minimum specified for each driven machine. If the estimated minimum horsepower specified is not adequate to satisfy the foregoing restrictions or any other requirements of these Specifications, the motor with the required horsepower shall be supplied at no additional cost to the Owner. In addition, any changes caused by increase in motor horsepower shall be made by the Contractor at no additional cost to the Owner; such changes may involve circuit breakers, magnetic starters, motor feeder conductors, conduit sizes, etc. 2. Exempt Motors: Motors which are for valve operators, submersible pumps, or motors which are an integral part of Standard Manufactured Equipment, i.e., non- NEMA mounting, common shaft with driven element, part of domestic or commercial use apparatus may be excepted from these Specifications to the extent that such variation reflects a necessary condition of motor service or a requirement of the driven equipment.
2.3 DESIGN REQUIREMENTS
A. General: All electric motors shall comply with ANSI/NEMA MG 1 - Motor and Generator.
B. NEMA Design: Electric motors shall be NEMA Design B, (except as indicated in Equipment Specifications for motors controlled for variable speed operation and other special motors,) constant speed squirrel-cage induction motors having normal starting torque with low starting current. In no case shall starting torque or breakdown torque be less than the value in ANSI/NEMA MG 1. Motors shall be suitable for the starting method indicated on the Electrical Drawings.
BC&A MOTORS 250HP AND LESS JVWCD PAGE 16222-3 CENTRAL PIPELINE PROJECT
C. Motor Voltage Ratings: Motors shall have voltage ratings in accordance with the following, unless otherwise indicated:
1. Voltage: a. All motors ½ hp and larger shall be 208V, 3 phase unless otherwise indicated on the Drawings. 2. Motors driving identical machines shall be identical. 3. All motors 1 hp and larger shall be “Premium Efficiency” motors as defined in NEMA MG-1. 4. Horsepower as indicated on the Drawings: a. Horsepower ratings shown on the drawings are based on Vendor’s estimates. Provide motors sized for the load of the actual equipment furnished. 5. Service Factor: a. Provide motors rated at 1.15 Service Factor. b. Provide motors capable of operating continuously at 1.15 Service Factor at project altitude. 1) Without exceeding Class B temperature rise limits where motors are provided with Class F insulation. 2) Without exceeding Class F temperature rise limits where motors are provided with Class H insulation. 6. Torque: a. Provide motors that develop sufficient torque for acceleration to full speed at voltage 10 percent less than motor nameplate rating. b. When started using reduced voltage starters: 1) Provide motors that develop sufficient torque for acceleration to full speed. c. NEMA Design B except where driven load characteristics require other than normal starting torque. 1) In No case shall starting torque or breakdown torque be less than the values specified in NEMA MG-1. 7. Enclosures: a. As indicated n the individual equipment Specifications or as specified in this section. b. Totally Enclosed Fan Cooled: 1) Cast iron conduit box. 2) Tapped drain holes with Type 316 stainless steel plugs for frames 286T and smaller, and automatic breather and drain devices for frames 324T and larger. c. Explosion-Proof: 1) Tapped drain holes with corrosion resistant plugs for frames 286T and smaller and automatic breather and drain devices for frames 324T and larger. d. Lifting Devices: All motors weighing 265 pounds (120 kilograms) or more shall have suitable lifting devices for installation and removal. 8. Manufactured with cast iron frames in accordance with NEMA MG-1.
BC&A MOTORS 250HP AND LESS JVWCD PAGE 16222-4 CENTRAL PIPELINE PROJECT 9. Nameplates: a. Provide all motors with a permanent, stainless steel nameplate indelibly stamped or engraved with: 1) NEMA Standard motor data. 2) Bearing description and lubrication instructions. 10. Hardware: a. Type 316 stainless steel. 11. Conduit Boxes: a. Cast iron or stamped steel. b. Split from top to bottom. c. Provide gaskets at the following interfaces: 1) Frames and conduit boxes. 2) Conduit boxes and box covers. d. Rotatable through 360 degrees in 90 degree increments. e. Exceeding the dimensions defined in NEMA MG-1. f. Provide grounding lugs inside conduit boxes for motor frame grounding. 12. Motor Bearings: a. Antifriction. b. Regreasable and initially filled with grease. c. Pumps Motor ion excess of 100 HP shall have oil lubricated bearings. d. Bearings and lubrication suitable for ambient temperature and temperature rise. e. Suitable for intended application and have ABMA L-10 rating life of 60,000 hours or more. f. Fit bearings with easily accessible grease/oil supply, flush, drain, and relief fittings using extension tubes where necessary. g. Where specified in the equipment specifications, provide split-sleeve type hydrohdynamic radial bearings. Provide a bearing isolator to protect bearings from contaminants. 13. Insulation Systems: a. Motors Installed in Ambient Temperatures of 40 degrees Celsius or less: 1) Provide Class F insulation. 2) Design temperature rise consistent with Class B insulation. 3) Rated to operate at an ambient temperature of 40 degrees Celsius and at the altitude where the motor will be installed. b. Motors Installed in Ambient Temperatures of 40 degrees Celsius and 65 degrees Celsius: 1) Provide Class H insulation. 2) Design temperature rise consistent with Class F insulation. 3) Rated to operate at an ambient temperature of 65 degrees Celsius and at the altitude where the motor will be installed. 14. Motor Leads: a. Insulated leads with non-wicking, non-hydroscopic material. Class F insulation. 15. Noise: a. Maximum operating noise level of 85dB measured as per IEEE 85.
BC&A MOTORS 250HP AND LESS JVWCD PAGE 16222-5 CENTRAL PIPELINE PROJECT
B. Submersible Motors:
1. Enclosures: a. Totally Enclosed Non-Ventilated (TENV) watertight casing. b. Smooth outer surface. Cooling fins may clog with solids and are not acceptable. c. Inner and outer shaft seals separated by an oil chamber. 2. Cooling: a. Suitable continuous operation in totally, partially, or nonsubmerged condition without overheating. b. Convection cooling only. c. Water jackets and oil cooling are not acceptable. 3. Electrical Cables: a. Wire unit without splices. Coordinate with Contractor to ensure cables of adequate length. b. Epoxy encapsulated cable entry into terminal box. 4. Insulation: a. Sealed moisture resistant windings. 5. Motor Protection (as required in equipment spec): a. Provide temperature detection in motor windings. b. Provide moisture detection in motor housing. c. Provide associated electronics and relaying in a separate enclosure to be mounted remotely.
C. Vertical Motors:
1. Enclosures: a. Weather protected Type II (WPII) where installed outdoors. b. Weather protected Type I (WPII) where installed indoors. 2. Thrust Bearings: a. Selected for combined rotor and driven equipment loads. b. Coordinate with driven equipment supplier for maximum vertical thrust of driven equipment.
D. Variable Frequency Drive Motors
1. Compatible with the variable frequency drives specified. 2. Inverter duty rated and labeled. 3. Meet the requirements of NEMA MG-1 Part 31. 4. Winding insulation meets the requirements of NEMA MG-1 Part 31.4.4.2.
5. Capable of running continuously at 1/10th of full speed, with no harmful effects or overheating. 6. Service factor of 1.0 when driven by VFD.
E. Motors Installed in Corrosive Environments:
1. Nameplate indicating conformance to IEEE 841. 2. Stator double dipped in varnish and baked.
BC&A MOTORS 250HP AND LESS JVWCD PAGE 16222-6 CENTRAL PIPELINE PROJECT 3. Stator and rotor coated with corrosion resistant epoxy. 4. Frame, brackets, fan guard and conduit box coated with minimum of two coats of epoxy paint. 5. Withstand salt spray tests as per ASTM B-117. 6. Suitable for hose down areas.
F. Single Phase Motors:
1. Capacitor start type rated for operation at 115 volts, 60 hertz, unless otherwise specified or as indicated on the Drawings. 2. Totally enclosed, fan cooled motors manufactured in accordance with NEMA MG-1. 3. Ball Bearings: Sealed. 4. ½ Horsepower or Less Fan Motors: a. Split-phase or shaded pole type when standard for the equipment. b. Open type when suitably protected from moisture, dripping water, and lint accumulation. 5. Wound rotor or commutator type single-phase motors only when their specific characteristics are necessary for application and their use is acceptable to the Engineer. 6. Integral overload protection.
2.4 ACCESSORIES
A.
2.5 SOURCE QUALITY CONTROL
A. Factory Testing
1. Perform factory tests in accordance with: a. IEEE 112 for three phase motors. b. IEEE 114 single phase motors. 2. Furnish copies of test reports. 3. Include testing of: a. No load current. b. Locked rotor current. c. Winding resistance. d. High potential. 4. Tests required on motors 250 hp and larger: a. Manufacturer’s routine test (use polarization index voltage = 5000V for insulation resistance tests). b. Efficiency and power factor versus load test performed at rated speed and 50 percent, 75 percent, 90 percent, and 100 percent of rated load. The curves from the motor tests shall be submitted for information.
BC&A MOTORS 250HP AND LESS JVWCD PAGE 16222-7 CENTRAL PIPELINE PROJECT c. The maximum allowable residual unbalance in each correction plane (journal) shall be calculated using the following equation:
U = 4 W/N Where: U = residual correction plane unbalance, in ounces-inches W = static correction plane journal loading, in pounds N = maximum specified operating speed, in revolutions per minute
PART 3 – EXECUTION
3.1 INSTALLATION
A. Install motors in accordance with manufacturer’s instructions.
B. electrical work involving connections, controls, switches, disconnects, etc., shall be performed as provided in the applicable sections of Division 16.
3.2 FIELD QUALITY CONTROL
A. Before start-up perform insulation resistance test on each motor furnished or installed on this project.
1. Windings energized to 1000 volts D.C. for one minute. 2. Resistance measured at the end of the test, recorded, and submitted to the Engineer for review. 3. Inform the Engineer of any unusual or unacceptable test results.
3.3 Visual and mechanical inspection for Motors and their Rotating Machinery:
A. Compare equipment nameplate information with the Drawings and Specifications.
B. Inspect physical and mechanical condition.
C. Inspect for proper anchorage, alignment, and grounding.
D. Inspect air baffles, filter media, cooling fans, slip rings, brushes and brush rigging.
E. Inspected bolted electrical connections for high resistance by one of the following:
1. Use of low resistance ohmmeter. 2. Calibrated torque wrench. 3. Thermographic survey.
F. Verify correct application of appropriate lubrication and lubrication systems.
BC&A MOTORS 250HP AND LESS JVWCD PAGE 16222-8 CENTRAL PIPELINE PROJECT G. Verify the absence of unusual mechanical or electrical noise or signs of overheating during initial test run.
H. Special tests as suggested by manufacturer, such as gap spacing and pedestal alignment shall be made where applicable.
3.4 Electrical tests:
A. Perform resistance measurements through bolted connections with a low resistance ohmmeter.
B. Perform insulation resistance test in accordance with ANSI/IEEE43. Test voltage shall be as specified by the manufacturer:
1. On motors 200 HP and smaller, test duration shall be one minute. Calculate dielectric absorption ratio using resistance measurements at 20 seconds and 60 seconds. 2. On motors larger than 200 HP, test duration shall be 10 minutes. Calculate polarization index using resistance measurements at one minute and 10 minutes. a. Perform stator resistance test phase-to-phase. b. Perform insulation power-factor or dissipation-factor tests. c. Perform surge comparison tests. d. Verify operation of motor space heater. e. Perform a rotation test to ensure correct shaft direction. f. Measure no load and full load running current and compare to nameplate. g. Observe proper operation and sequence of any reduced voltage starters. h. Perform vibration base line test. Amplitude to be plotted vs. frequency. i. Check all protective devices in accordance with other sections of these specifications.
j. After start-up of each motor, the current on each phase shall be measured: 1) At no load. 2) At defined load: 3) Record the voltage of each phase to round during this test. 4) Inrush current.
C. Measurements shall be recorded and submitted to the Engineer.
3.5 Test Values:
A. Insulation resistance should be not less than 10 mega-ohms.
B. Dielectric absorption ratio or polarization index readings less than the manufacturer’s recommended values (not less than three for polarization index or 1.4 for dielectric absorption ratio) shall be investigated.
BC&A MOTORS 250HP AND LESS JVWCD PAGE 16222-9 CENTRAL PIPELINE PROJECT C. Motor measured full load current shall not exceed nameplate value.
D. Vibration amplitudes shall not exceed values furnished by manufacturer.
END OF SECTION
BC&A MOTORS 250HP AND LESS JVWCD PAGE 16222-10 CENTRAL PIPELINE PROJECT SECTION 16422 MOTOR STARTERS PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. Section includes the following motor starters rated 600 V and less:
1. Full-voltage magnetic. 2. Reduced-voltage solid state.
B. For installation in motor control centers, control panels and as standalone devices.
C. Related Section:
1. Division 16 Section "Variable Frequency Drives" for general-purpose, ac, adjustable-frequency, pulse-width-modulated drives. 2. Division 16 Section “Low Voltage Motor Control Centers”. 3. Division 16 Section “Electrical General Provisions”. 4. Contract Documents are a single integrated document, and as such all Divisions and Sections apply. It is the responsibility of the Contractor and its Sub- Contractors to review all sections to insure a complete and coordinated project.
1.3 DEFINITIONS
A. CPT: Control power transformer.
B. MCCB: Molded-case circuit breaker.
C. MCP: Motor circuit protector.
D. N.C.: Normally closed.
E. N.O.: Normally open.
F. SCR: Silicon-controlled rectifier.
G. Definitions of terms and other electrical considerations as set forth in the:
1. Institute of Electrical and Electronic Engineers. 2. National Fire Protection Association. a. NFPA 70; National Electrical Code.
BC&A MOTOR STARTERS JVWCD 16422- 1 CENTRAL PIPELINE PROJECT 1.4 SYSTEM DESCRIPTION
A. General Requirements
1. Starters shall be incorporated into motor control centers, individual starters, combination starters, and control panels as reflected on the drawings and noted in the specifications. 2. Ratings, components, and features shall be as shown on the single-line diagrams, control diagrams, details and schedules on the drawings. 3. All components shall be newly manufactured and of the latest construction series of the manufacturer.
1.5 SUBMITTALS
A. Furnish complete submittals in accordance with Sections 01300 and 16050.
B. Product Data
1. Manufacturer. 2. Technical information. 3. Complete nameplate schedule. 4. Dimensions: a. Overall length. b. Overall width. c. Overall height. 5. Complete Bill of Material. 6. List of recommended spare parts. 7. Painting and finish procedures and materials list. 8. Manufacturer and Amperage rating for the following: a. Overload relays. b. Motor circuit protectors. c. Circuit breakers. d. Fuses. e. Protective relays. 9. Confirmation that the overload relay class meets the requirements of the equipment and motor suppliers for each starter. 10. Confirmation that any reduced voltage solid-state starters are matched to the respective driven loads at the installed conditions and will reliably accelerate the driven load.
C. Shop Drawings
1. Layout drawings. 2. Provide fully dimensioned and to scale layout drawings which include: a. All equipment furnished. b. Interfaces with other equipment. c. Allowable top and bottom conduit windows. d. Nameplate legends. e. Short-circuit current rating of integrated unit. 3. Elementary schematic diagrams. 4. One diagram for each and every starter and/or contactor. BC&A MOTOR STARTERS JVWCD 16422- 2 CENTRAL PIPELINE PROJECT 5. Wiring diagrams showing wire numbers for all internal control wires. 6. Show lug sizes, type, and manufacturer based on the cable size as specified or indicated on the project drawings.
D. Operation and Maintenance Data
1. Submit complete operating and maintenance instructions presenting full details for care and maintenance of equipment of every nature furnished and/or installed under this section. Manuals shall include the following: 2. Electrical ratings a. Phase. b. Wire. c. Voltage. d. Ampacity. 3. Complete Bill of Material. 4. Manufacturer’s operating and maintenance instructions for the starters and/or contactors and all component parts, including; a. Overload relays and heater elements. b. Protective devices (fuses, breakers, protective relays, etc.). c. Pilot devices. 5. Complete renewal parts list. 6. 11” x 17” prints of final as-built record drawings.
1.6 QUALITY ASSURANCE
A. Regulatory Requirements
1. Comply with NFPA 70, National Electric Code. 2. All portions and components of the starters and/or contactors shall bear UL or other nationally recognized independent testing laboratory labels. 3. Certifications: a. The manufacturer shall certify that the reduced voltage solid state starter will reliably control the acceleration and of the driven load at the installed conditions. b. Failure of the manufacturer to provide said certification shall be interpreted as to mean that the manufacturer has agreed that the reduced voltage solid state starter is matched to the driven load at the installed conditions and will function without fault. If the reduced voltage solid state starter fails to perform as desired the manufacturer shall replace or modify the reduced voltage solid state starter in order to achieve the desired operational conditions, as directed by the Engineer, at no additional costs to the Owner.
1.7 DELIVERY, STORAGE, AND HANDLING
Store motor starters indoors in clean, dry space with uniform temperature to prevent condensation. Protect motor starters from exposure to dirt, fumes, water, corrosive substances, and physical damage.
BC&A MOTOR STARTERS JVWCD 16422- 3 CENTRAL PIPELINE PROJECT 1.8 PROJECT CONDITIONS
A. Environmental Limitations: Rate equipment for continuous operation, capable of driving full motor load, under the following conditions, unless otherwise indicated:
1. Ambient Temperature: Not less than minus 22 deg F and not exceeding 104 deg. 2. Altitude: Not exceeding 5000 feet. 3. Humidity: Equal to or less than 95 percent (noncondensing). 1.9 COORDINATION
A. Coordinate layout and installation of motor starters with other construction including conduit, piping, equipment, and adjacent surfaces. Maintain required workspace clearances and required clearances for equipment access doors and panels.
B. Coordinate sizes and locations of concrete bases with actual equipment provided. Cast anchor-bolt inserts into bases. Concrete, reinforcement, and formwork requirements are referenced in Division 16 Section “Electrical General Provisions”.
1.10 WARRANTY
A. Provide a full two year warranty that shall cover all parts and labor needed to replace any components associated with the starters and/or contactors for a period of two years from the complete and final acceptance of the total project.
1. Warranty requirements that require the return of parts and Owner installation of said parts will not be accepted.
1.11 EXTRA MATERIALS
PART 2 - PRODUCTS
2.1 FULL-VOLTAGE STARTERS AND CONTACTORS A. General Requirements for Full-Voltage Starters: Comply with NEMA ICS 2, general purpose, Class A.
B. Magnetic Starters: Full voltage, across the line, electrically held.
1. Manufacturers: Subject to compliance with requirements, provide products by one of the following: a. Eaton Electrical Inc.; Cutler-Hammer Business Unit. b. General Electric Company; GE Consumer & Industrial - Electrical Distribution. c. Rockwell Automation, Inc.; Allen-Bradley brand. d. Square D; a brand of Schneider Electric. e. Or Equal.
BC&A MOTOR STARTERS JVWCD 16422- 4 CENTRAL PIPELINE PROJECT 2. Rating: The minimum size shall be a NEMA size 0. Verify motor ratings and coordinate starter and overload trip rating with actual horsepower and nameplate current ratings of motor installed. a. If motors provided are different in horsepower rating than those specified or indicated on the drawings, provide starters of sufficient size to accommodate the specific motors furnished. 3. Configuration: Non-reversing or Reversing as required for the application and as shown on the drawings. 4. Contactor Coils: Pressure-encapsulated type, and with coil transient suppressors as required for voltage or size of the coil. a. Operating Voltage: Depending on contactor NEMA size and line-voltage rating, manufacturer's standard matching control power or line voltage. 5. Power Contacts: Totally enclosed, double-break, silver-cadmium oxide; assembled to allow inspection and replacement without disturbing line or load wiring. 6. Magnetic contactors shall be factory adjusted and chatter free. 7. Control Circuits: Normally the control voltage will be 120V ac, however 24V dc, may be used as required for manufacturer’s special applications, and as shown on the drawings. If other control voltages are used they shall be as shown on the drawings. a. 120V ac shall be obtained from integral CPT, with primary and secondary fuses, CPT shall be of sufficient capacity to operate integral devices and remotely located pilot, indicating, and control devices. b. 24V dc shall be obtained from power supply, with primary and secondary fuses, control power source shall be of sufficient capacity to operate integral devices and remotely located pilot, indicating, and control devices. 8. Solid-State Overload Relay: a. Switch or dial selectable for motor running overload protection. b. Sensors in each phase. c. Class 10/20 selectable tripping characteristic selected to protect motor against voltage and current unbalance and single phasing. d. The overload relay shall be set to protect the motor in the application shown on the drawings and for the size of the motor shown. e. Mount extended overload reset buttons to be accessible for operation without opening door of enclosure. f. Isolated overload alarm contact for indication and connection to the SCADA system as shown on drawings. C. Combination Magnetic Starter: Factory-assembled combination of magnetic starter, overcurrent protective device, and disconnecting means. The type of overcurrent protective device used shall be as shown on drawings.
1. The overcurrent protective device shall be rated for the short circuit as shown on the drawings. The overcurrent protective device and the starter shall be rated together to provide Type 2 coordination for starter protection from very high short circuit currents.
2. MCP Disconnecting Means: a. UL 489, NEMA AB 1, and NEMA AB 3, with interrupting capacity to comply with available fault currents, instantaneous-only circuit breaker
BC&A MOTOR STARTERS JVWCD 16422- 5 CENTRAL PIPELINE PROJECT with front-mounted, field-adjustable, short-circuit trip coordinated with motor locked-rotor amperes. b. Lockable Handle: Accepts three padlocks and interlocks with cover in closed position. c. Auxiliary contacts "a" and "b" arranged to activate with MCP handle are required as shown on drawings.
2.2 ENCLOSURES
A. Motor starters: NEMA ICS 6, to comply with environmental conditions at installed location.
1. For starters in low voltage motor control centers, the enclosure type is specified in section 16444, “Low Voltage Motor Control Centers”. 2. Enclosures for combination starters shall be the type as specified on the drawings or in section 16050 “Electrical General Provisions”.
2.3 ACCESSORIES
A. General Requirements for Control Circuit and Pilot Devices: NEMA ICS 5; factory installed in controller enclosure cover unless otherwise indicated.
A. Manual Operator Interface Devices: 1. General: a. Provide operator pushbuttons, switches, and pilot lights, from a single manufacturer. b. Size: 1. 30.5mm. c. Lamp Color: 1. On/Running/Start/Open: Green. 2. Close/Off/Stop: Red. 3. Power: White. 4. Alarm: Red. 5. Status or Normal Condition: White. 6. Opened: Amber. 7. Closed: Blue. 8. Failure: Red. d. Pilot lights: 1. Type: a. LED for all interior installations. b. Full Voltage for exterior installations. 2. Push to Test. 3. LED Lamp. 4. Manufacturer: One of the following a. Allen Bradley Type 800T. b. Square D Class 9001 Type K. c. General Electric Type CR104P. d. IDEC TWTD
BC&A MOTOR STARTERS JVWCD 16422- 6 CENTRAL PIPELINE PROJECT
B. Auxiliary Contacts
1. Contact ratings as per NEMA A600 rating. 2. Auxiliary contacts rated 10 Amps at 600 volts. 3. Provide all contacts shown on the drawings, and any additional contacts required for proper operation. 4. Provide at least 1 normally open and 1 normally closed spare auxiliary contact with each starter.
C. Control Relays: Auxiliary relays and adjustable time-delay relays.
1. General
a. For all types of 120 VAC relays, provide transient surge protection across the coil of each relay.
b. For all types of 24 VDC relays, provide a free-wheeling diode across the coil of each relay.
2. General Purpose:
a. Magnetic control relays.
b. NEMA A300 rated:
1) 300 Volts.
2) 10 Amps continuous.
3) 7,200 VA make.
4) 720 VA break.
c. Plug-in type.
d. LED indication for relay energized.
e. Coil voltages: 120VAC .
f. Minimum poles: 2PDT.
g. Touch safe design: All connection terminals to be protected against accidental touch.
h. Enclose each relay in a clear plastic heat and shock-resistant dust cover.
i. Quantity and type of contact shall be as shown on the Drawings or as needed for system compatibility.
j. Sockets for relays shall have screw-type terminals. BC&A MOTOR STARTERS JVWCD 16422- 7 CENTRAL PIPELINE PROJECT k. Provide additional (slave/interposing) relays when the following occurs:
1) The number or type of contacts shown exceeds the contact capacity of the specified relays.
2) Higher contact rating is required in order to interface with starter circuits or other equipment.
l. DIN rail mounting on 35mm rail.
m. Ice Cube type relays shall be provided with retainer clips to secure relay in socket.
n. Integrated label holder for device labeling.
o. Manufacturer: One of the following:
1) Phoenix Contact PLC series.
2) Potter and Brumfield Type KRP or KUP.
3) IDEC R* series. (* = H, J, R, S, U).
4) Allen Bradley Type 700 H Series.
5) Square D Type K.
D. Space heaters, with N.C. auxiliary contacts, to mitigate condensation in enclosures installed outdoors or in unconditioned interior spaces subject to humidity and temperature swings. Space heaters shall be installed when specified on the drawings.
E. Power factor correction capacitors shall be sized and provided by the starter manufacturer when they are shown on the drawings.
PART 3 - EXECUTION
3.1 EXAMINATION
A. Examine areas and surfaces to receive motor starters, with Installer present, for compliance with requirements and other conditions affecting performance of the Work.
B. Examine motor starters before installation. Reject motor starters with electronic circuitry that is moisture damaged or mold damaged.
C. Proceed with installation only after unsatisfactory conditions have been corrected.
3.2 INSTALLATION
A. For installation of motor starters in low voltage motor control centers see specification section 16444 “Low Voltage Motor Control Centers”.
BC&A MOTOR STARTERS JVWCD 16422- 8 CENTRAL PIPELINE PROJECT
B. Combination Starters shall be installed in accordance with manufacturer recommendations and as specified in this section.
C. Combination Wall-Mounted Starters: Install motor starters on walls with tops at uniform height unless otherwise indicated, and by bolting units to wall or mounting on lightweight structural-steel channels bolted to wall. For starters not at walls, provide freestanding racks as shown on the drawings.
D. Combination Floor-Mounted Starters: Install motor starters on 3-1/2 inch raised concrete housekeeping pad, unless otherwise indicated, as shown on the Contract Drawings.
Comply with requirements for concrete referenced in Division 16 Section “Electrical General Provisions”.
1. Install dowel rods to connect concrete base to concrete floor. Unless otherwise indicated, install dowel rods on 18-inch centers around the full perimeter of concrete base. 2. For supported equipment, install epoxy-coated anchor bolts that extend through concrete base and anchor into structural concrete floor. 3. Place and secure anchorage devices. Use setting drawings, templates, diagrams, instructions, and directions furnished with items to be embedded. 4. Install anchor bolts to elevations required for proper attachment to supported equipment.
E. Temporary Lifting Provisions: Remove temporary lifting eyes, channels, and brackets and temporary blocking of moving parts from enclosures and components.
F. Comply with NECA 1.
3.3 IDENTIFICATION
A. Identify motor starters, components, and control wiring. Comply with requirements for identification specified in Division 16 Section "Electrical Identification."
1. Identify field-installed conductors, interconnecting wiring, and components; provide warning signs. 2. Label each enclosure with engraved nameplate. 3. Label each enclosure-mounted control and pilot device.
3.4 CONTROL WIRING INSTALLATION
A. Install wiring between motor starters remote devices and control system. Comply with requirements in Division 16 Section "600 Volt or Less Wires and Cables."
B. Bundle, train, and support wiring in enclosures.
C. Connect selector switches and other automatic-control selection devices where applicable as shown on drawings.
BC&A MOTOR STARTERS JVWCD 16422- 9 CENTRAL PIPELINE PROJECT
3.5 FIELD QUALITY CONTROL
A. Perform tests and inspections.
1. Visual and Mechanical Inspection: a. Compare equipment nameplate data with Drawings and Specifications. b. Inspect physical and mechanical condition. c. Inspect anchorage, alignment, and grounding. d. Verify the unit is clean. e. Verify contactors: 1) Verify mechanical operation. 2) Inspect contact gap, wipe, alignment, and pressure are in accordance with manufacturer’s published data. B. Acceptance Testing Preparation:
1. Test insulation resistance for each enclosed controller, component, connecting supply, feeder, and control circuit. 2. Test continuity of each circuit.
C. Tests and Inspections:
1. Inspect starters, wiring, components, connections, and equipment installation. 2. Test insulation resistance for each enclosed-controller element, component, connecting motor supply, feeder, and control circuits. 3. Test continuity of each circuit. 4. Verify that voltages at controller locations are within plus or minus 10 percent of motor nameplate rated voltages. If outside this range for any motor, notify Owner before starting the motor(s). 5. Test each motor for proper phase rotation. 6. Perform each electrical test and visual and mechanical inspection stated in NETA Acceptance Testing Specification. Certify compliance with test parameters. 7. Correct malfunctioning units on-site, where possible, and retest to demonstrate compliance; otherwise, replace with new units and retest. 8. Manufacturer’s Field Service: Engage a factory-authorized service representative for startup and inspection of Reduced-Voltage Solid-State Starters. 9. Test and adjust controls, remote monitoring, and safeties. Replace damaged and malfunctioning controls and equipment.
D. Motor starters will be considered defective if they do not pass tests and inspections.
E. Prepare test and inspection reports including a certified report that identifies motor starters and that describes scanning results. Include notation of deficiencies detected, remedial action taken and observations after remedial action.
3.6 ADJUSTING
A. Set field-adjustable switches, auxiliary relays, time-delay relays, timers, and overload- relay pickup and trip ranges. BC&A MOTOR STARTERS JVWCD 16422- 10 CENTRAL PIPELINE PROJECT
B. Adjust overload-relay heaters or settings if power factor correction capacitors are connected to the load side of the overload relays.
C. Adjust the trip settings of MCPs and thermal-magnetic circuit breakers with adjustable instantaneous trip elements. Initially adjust to six times the motor nameplate full-load ampere ratings and attempt to start motors several times, allowing for motor cooldown between starts. If tripping occurs on motor inrush, adjust settings in increments until motors start without tripping. Do not exceed eight times the motor full-load amperes (or 11 times for NEMA Premium Efficient motors if required). Where these maximum settings do not allow starting of a motor, notify Engineer and Owner before increasing settings.
D. Set field-adjustable switches and program microprocessors for required start and stop sequences in reduced-voltage solid-state starters.
3.7 TRAINING
A. Provide the services of the manufacturer’s technical representative to provide training in start-up, adjustment, and troubleshooting of the following equipment:
1. Reduced Voltage Solid-State Starters: minimum of 8 hours at the Owner’s facility. END OF SECTION
BC&A MOTOR STARTERS JVWCD 16422- 11 CENTRAL PIPELINE PROJECT
SECTION 16476 LOW VOLTAGE CIRCUIT BREAKERS
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and other Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. Section Includes:
1. Requirements for Circuit Breakers. a. Molded case circuit breakers. b. Molded case switches. c. Motor circuit protectors. d. Low voltage metal enclosed (large air iron frame) circuit breakers.
B. Related Sections:
1. Division 16 Section “Electrical General Provisions”. 2. Division 16 Section “Electrical Identification”. 3. Contract Documents are a single integrated document, and as such all Divisions and Sections apply. It is the responsibility of the Contractor and its Sub- Contractors to review all sections to insure a complete and coordinated project.
1.3 REFERENCES
A. Molded Case Circuit Breakers
1. U.L.: a. U.L. 489 - Branch Circuit and Service Circuit Breakers. b. U.L. 1087 - Molded Case Switches. 2. NEMA: a. AB-1 - Standards Publication Molded Case Circuit Breakers. 3. Federal Specifications: a. WC -375A - Circuit Breaker, Molded Case, Branch Circuit and Service.
B. ANSI Large Air Iron Frame Circuit Breakers
1. NEMA: a. SG3 - Low Voltage Power Circuit Breakers. 2. ANSI: a. C37.13 - American National Standards for Low Voltage AC Power Circuit Breakers used in Enclosures (IEEE Std 20). b. C37.16 - Preferred Ratings, Related Requirements and Application Recommendations for Low-Voltage Power Circuit Breakers and AC Power Circuit Protectors.
BC&A LOW VOLTAGE CIRCUIT BREAKERS JVWCD 16476 - 1 CENTRAL PIPELINE PROJECT c. ANSI C37-50 - Test Procedures for Low-Voltage AC Power Circuit Breakers used in Enclosures
1.4 DEFINITIONS
A. Definitions of terms and other electrical considerations as set forth in the:
1. National Electrical Code. 2. Institute of Electrical and Electronic Engineers. 3. National Fire Protection Association.
1.5 System Description
A. Furnish molded case, insulated case, power type, or motor circuit protector circuit breakers as indicated on the drawings and connect to form a completed system.
B. Circuit breakers must be of the current and voltage ratings indicated and be capable of interrupting the available fault current.
C. Where circuit breakers are used as disconnects for miscellaneous over-current protection, provide automatic type enclosed units with the indicated ratings and complying with applicable requirements (including manufacturer) for circuit breakers as specified.
1.6 SUBMITTALS
A. Furnish complete submittals in accordance with Sections 01300 and 16050.
B. Product Data:
1. Catalog Cut Sheets 2. Complete data sheets indicating: a. Manufacturer. b. Type of enclosure. c. Voltage rating. d. Current rating. e. Amperage rating. f. Complete dimensional and weight information.
C. Operating Manuals
1. Furnish complete operating and maintenance instructions presenting full details for care and maintenance of equipment of every nature furnished and/or installed under this section. a. Complete electrical ratings. b. Complete renewal parts list.
1.7 WARRANTY
A. All circuit breakers shall be 100% warranted for a period of not less than two years from the date of final acceptance by the ENGINEER. BC&A LOW VOLTAGE CIRCUIT BREAKERS JVWCD 16476 - 2 CENTRAL PIPELINE PROJECT
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. Acceptable Manufacturers:
1. Cutler-Hammer. 2. Square D. 3. General Electric.
2.2 EQUIPMENT
A. Breakers General
1. All breakers shall have temperature insensitive trips.
B. Molded Case Circuit Breakers
1. Molded case circuit breakers for distribution panelboards and motor control centers. a. Basic circuit breaker must be trip free with a quick-make, quick-break mechanism. b. Trip indicating handle position. c. Trip mechanism as indicated on drawings: 1) Thermal magnetic. 2) Thermal high magnetic. 3) Solid State. a) Adjustable long time pickup-, ampere setting to determine the value of current that the breaker will carry indefinitely. b) Adjustable long time delay- varies the time it will take the breakers to trip under sustained overload. c) Adjustable short time pickup- controls the level of high current the breaker will carry for short periods of time. d) Adjustable short time delay- controls the length of time the breaker will carry a high current without tripping. e) Adjustable instantaneous pickup- controls level at which immediate tripping of breaker occurs. (1) Instantaneous trip function may be eliminated on main breakers, refer to drawings. f) Adjustable ground fault pickup- controls the level at which the breaker will trip under a ground fault condition (where shown on the drawings). g) Adjustable ground fault delay- controls the time that a ground fault can exist without tripping the breaker (where ground fault feature is shown on the drawings). h) Long time pickup indicator- provides a visual indication that the breaker is experiencing an overload condition. i) Fault indicators shall be either mechanical or powered from a separate battery and charger that shall be an integral component of the switchboard. BC&A LOW VOLTAGE CIRCUIT BREAKERS JVWCD 16476 - 3 CENTRAL PIPELINE PROJECT (1) Indicator for overload fault trip. (2) Indicator for short circuit fault trip. (3) Indicator for ground fault trip. 2. Provide non-automatic trip breakers (molded case switches) only where specifically indicated on the contract drawings or in the specifications.
2.3 COMPONENTS
A. Enclosures
1. Furnish enclosures consistent with the area classification and NEMA designation as indicated on the plans and specifications.
PART 3 - EXECUTION
3.1 EXAMINATION
A. Examine elements and surfaces to receive safety switches for compliance with installation tolerances and other conditions affecting performance of the Work.
B. Proceed with installation only after unsatisfactory conditions have been corrected.
3.2 INSTALLATION
A. Arrange all breakers to correspond exactly with the schedules.
B. In damp or wet areas, mount the enclosures on Unistrut type mounting channels that run vertically so that water and moisture may flow freely behind enclosure.
3.3 FIELD QUALITY CONTROL
A. Low Voltage Molded Case and Insulated Case Circuit Breakers:
1. Visual and Mechanical Inspection: a. Compare equipment nameplate data with Drawings and Specifications. b. Inspect physical and mechanical condition. c. Inspect anchorage and alignment. d. Circuit breaker shall be checked for proper mounting, conductor size and feeder designation. e. Operate circuit breaker to ensure smooth operation. f. Check tightness of connection with torque wrench in accordance with manufacturer’s recommendations. g. Inspect operating mechanism, contacts, and arc chutes in unsealed units. 2. Electrical tests for breakers in excess of 200 Amp trip ratings: a. Perform resistance measurements through bolted connections with a low resistance ohmmeter. b. Time-current characteristic tests shall be performed by passing 300 percent rated current through each pole separately. Trip time shall be determined: 1) Determine long-time pickup. 2) Determine short-time pickup. BC&A LOW VOLTAGE CIRCUIT BREAKERS JVWCD 16476 - 4 CENTRAL PIPELINE PROJECT c. Instantaneous pickup current shall be determined by run-or pulse method: 1) Clearing times should be within 4 cycles or less. d. Insulation resistance shall be determined pole to pole, across pole and pole to ground. 1) Circuit breaker shall be closed. 2) Test voltage shall be 1000 volts dc applied for one minute. e. Perform adjustments for final setting in accordance with the Short Circuit and f. Coordination Study. 3. Test values: a. Contact resistance shall be compared to adjacent poles and similar breakers: 1) Deviations of more than 50 percent shall be investigated. b. Insulation resistance shall not be less than 100 megohms. c. All trip times shall fall within manufacturer’s published time current curves: 1) Circuit breakers exceeding maximum time shall be replaced. d. Instantaneous pickup current levels should be within 20 percent of manufacturer’s published values.
B. Low Voltage Air Circuit Breaker ANSI Class Breakers:
1. Visual and mechanical inspection: a. Compare equipment nameplate data with Drawings and Specifications. b. Inspect physical and mechanical condition. c. Inspect anchorage and alignment and grounding. d. Verity that all maintenance devices are available for servicing and operating the breaker. e. Verify the unit is clean. f. Verify the arc chutes are intact. g. Perform all mechanical operator and contact alignment tests in accordance with manufacturer’s instruction manual. h. Check cell fit and element alignment. i. Check tightness of connections using a calibrated torque wrench. j. Verify racking mechanism operation. k. Lubrications requirements. 1) Verify appropriate lubrication on moving current-carrying parts. 2) Verify appropriate lubrication on moving and sliding surfaces. 2. Electrical tests: a. Perform resistance measurements through bolted connections with a low resistance ohmmeter. b. An insulation resistance test shall be performed on each pole, phase-to- phase and phase to ground with the circuit breaker closed, and across each open pole: 1) Test voltage shall be 1000 volts dc applied for one minute. c. Perform a contact/pole-resistance test. d. Make adjustments to the trip settings in accordance with the Short Circuit and coordination study. e. Minimum pickup current shall be determined by primary current injection. f. Long time delay shall be determined by primary injection at 300 percent pickup current.
BC&A LOW VOLTAGE CIRCUIT BREAKERS JVWCD 16476 - 5 CENTRAL PIPELINE PROJECT g. Short time pickup and time delay shall be determined by primary injection of current. h. Instantaneous pickup current shall be determined by primary injection. i. Trip unit reset characteristics shall be verified. j. Verify correct operation of any auxiliary features such as trip and pickup indicators, zone interlocking, electrical close and trip operation, trip-free, antipump function, trip unit battery condition, and reset all trip logs and indicators. k. Verify operation of charging mechanism. 3. Test Values: a. Contact resistance shall be determined in micro-ohms: 1) Any values exceeding 200 micro-ohms or any values which deviate from adjacent poles or similar breakers by more than 50 percent should be investigated. b. Insulation resistance shall not be less than 50 megohms. c. Pickup currents and trip times should fall within manufacturer’s published time-current characteristic tolerance ban.
END OF SECTION
BC&A LOW VOLTAGE CIRCUIT BREAKERS JVWCD 16476 - 6 CENTRAL PIPELINE PROJECT SECTION 16500 LIGHTING
PART 1 – GENERAL
1.1 THE REQUIREMENT
A. The CONTRACTOR shall provide lighting fixtures, and accessories for all lighting systems, complete and operable, in accordance with the Contract Documents.
1.2 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS
A. Commercial Standards
National Electric Code
Underwriters Laboratories
ANSI C82.1 Specifications for Fluorescent Lamp Ballasts
Standards of the Certified Ballast Manufacturer's Association
1.3 CONTRACTOR SUBMITTALS
A. Submit the following in accordance with the requirements of Section 01300 - Contractor Submittals.
1. Shop drawings and catalog data. 2. Catalog literature for each fixture. Each such submittal shall clearly describe materials, type of diffuser, hardware, gasketing, reflector and chassis, finish, and ballast. 3. Complete literature for each fixture substitutions with incandescent lamps in excess of 200 watts or HPS Sodium sources in excess of 75 watts. Submittals for other fixtures shall be sufficient for competent comparison of the proposed fixture to the originally specified fixture. Photometric data shall include coefficients of utilization, average brightness, candle power distribution curves, and lumen output chart. 4. Ballast catalog data indicating lamp wattage, input watts, sound rating, power factor, and type of ballast. Data for outdoor ballast shall be include low temperature starting characteristics.
B. Substitutions for indicated fixtures shall be based upon quality of construction, light distribution, appearance, and maintenance.
BC&A LIGHTING JVWCD PAGE 16500-1 CENTRAL PIPELINE PROJECT
1.4 QUALITY ASSURANCE
A. Lighting fixtures shall be stored in their original cartons from the manufacturers until the time of installation.
1.5 CLEANUP
A. Fixture lenses, diffusers, and reflectors shall be cleaned just prior to the time the system demonstrations.
B. Fixture trim, including poles and support brackets, where finish has been damaged, shall be refinished.
PART 2 – PRODUCTS
2.1 FIXTURES – GENERAL
A. All fixtures shall be prewired with leads of 18-AWG, minimum, for connection to building circuits.
2.2 INTERIOR FIXTURES
A. Interior fluorescent fixtures without diffusers shall be furnished with end plates. Where diffusers are required, they shall be of high molecular strength acrylic. Minimum thickness of the acrylic shall be 0.125 inches for all diffusers, except that those on 4-foot square fixtures shall be 0.187 inches thick.
2.3 LAMPS
A. Lamps shall be first-line Sylvania, Philips, or equal.
B. Fluorescent lamps shall be cool/white unless otherwise indicated. Incandescent lamps shall be frosted unless a fixture lighting control system requires clear globe lamps. High- pressure sodium lamps shall be "color corrected." Unless otherwise indicated, lamps shall be suitable for operation in any burning position.
2.4 BALLASTS
A. Ballasts for fluorescent fixtures in office areas shall be high efficiency solid-state type and shall have a Class "A" sound rating. Such ballasts shall be of the low loss type. All ballasts shall be high power factor, Class P. Primary ballast voltage shall be suitable for use in the branch circuits indicated in the Contract Documents.
PART 3 – EXECUTION
3.1 LIGHTING FIXTURES
A. Lighting fixtures shall be provided complete at each outlet in accordance with the Fixture Schedule.
BC&A LIGHTING JVWCD PAGE 16500-2 CENTRAL PIPELINE PROJECT
B. Lighting fixtures shall be installed plumb and square with building and wall intersections. In all cases, fixture locations shall be coordinated with work of other trades to prevent obstruction of light from the fixtures. Fixtures shall be installed in accordance with the architectural reflected ceiling Drawings. Unless otherwise indicated, fixtures shall be centered on ceiling tiles.
- END OF SECTION -
BC&A LIGHTING JVWCD PAGE 16500-3 CENTRAL PIPELINE PROJECT
DIVISION 17 INSTRUMENTATION
SECTION 17050 PROCESS CONTROL AND INSTRUMENTATION SYSTEMS GENERAL
PART 1 – GENERAL
1.1 SUMMARY
A. General requirements that apply to all process control and instrumentation systems for the entire project.
B. Related Sections:
1. In addition to the responsibilities listed below, the System Supplier shall be responsible for all requirements of Division 16 and Division 17. 2. The Contract Documents are a single integrated document, and as such all Divisions and Sections apply. It is the responsibility of the CONTRACTOR and its subcontractors to review all sections to insure a complete and coordinated project. 3. Items involving electrical, control, and instrumentation construction may be shown on drawings or referred to in specifications that do no apply specifically to electrical, control and instrumentation systems. Because the Contract Documents are a single integrated document, it is the responsibility of the CONTRACTOR and its subcontractors to review all sections to insure a complete and coordinated project. 4. Items not involving electrical, control, and instrumentation construction may be shown on drawings or referred to in specifications that do apply specifically to electrical, control, and instrumentation systems. Because the Contract Documents are a single integrated document, it is the responsibility of the CONTRACTOR and its subcontractors to review all sections to insure a complete and coordinated project.
C. The Contract Drawings, Documents, and overall design has been based on non-certified information furnished by various equipment manufacturers. It is incumbent on the part of the CONTRACTOR and Instrumentation and Control System Contractor to include in the BID all material and labor needed to install the actual equipment furnished.
1. The CONTRACTOR and Instrumentation Control System Contractor shall note that the instrument equipments specifications, ladder logic diagrams, and installation details are based on non-certified vendor information and indicate minimum scope of supply from the equipment manufacturer. The CONTRACTOR and Instrumentation and Control System Contractor shall include all costs in its BID to add additional instruments, wiring, computer inputs/outputs, controls, conduit, interlocks, electrical hardware, etc., into the design based on the equipment manufacturer’s final certified vendor drawings. The CONTRACTOR and Instrumentation and Control System Contractor shall revise or produce new loop diagrams to meet the equipment manufacturer’s wiring requirements. Such changes to instrumentation and electrical work shall be incorporated into the scope of work at no additional cost to the OWNER in the light of the CONTRACTOR’s knowledge that non-certified vendor information has been used in the design.
BC&A PROCESS CONTROL AND INSTRUMENTATION JVWCD SYSTEMS GENERAL CENTRAL PIPELINE PROJECT PAGE 17050-1 1.2 REFERENCES
A. Codes and Regulator Compliance.
1. The equipment, materials, installation, and other WORK shall conform to all applicable regulations, standards, specifications, and codes which are current as of the date of the final inspection for this Contract. 2. Without limiting the generality of other requirements of these specifications, all WORK specified herein shall conform to or exceed the applicable requirements of the referenced documents to the extent that the requirements therein are not in conflict with the provisions of this Section; provided, that where such documents have been adopted as a code or ordinance by the public agency having jurisdiction, such code or ordinance shall take precedence. 3. The equipment, materials, installation, and other WORK shall conform to all applicable regulations, standards, specifications, and codes which are current as of the date of bidding for this Contract, including, but not limited to, those which are established by the following sources: a. International Society of Automation (ISA). b. National Electrical Manufacturers Association (NEMA). c. Occupational Safety and Health Administration (OSH). d. American National Standards Institute (ANSI). e. National Fire Protection Association (NFPA). f. Institute of Electrical and Electronic Engineers (IEEE). g. National Electrical Code (NEC). h. Insulated Cable Engineers Association (ICEA). i. Federal Communications Commission (FCC). j. Underwriters Laboratory (UL). k. Local Power and Telephone Companies. l. Local Authorities having jurisdiction over the WORK.
B. Where the requirements set forth in these Specifications or on the Drawings are greater or more rigid than the mandatory requirements referenced above, the applicable Specifications or Drawings shall govern.
C. In case of conflict between any mandatory requirements and Specifications or Drawings, the mandatory requirement shall be followed in each case, but only after submitting such proposed changes to the ENGINEER for approval.
D. Nothing contained in these Specifications or shown on the Drawings will be so construed as to conflict with any national, state, municipal, or local laws or regulations governing the installation of work specified herein, and all such acts, ordinances, and regulations, including the National Electrical Code, are hereby incorporated and made a part of these Specifications. All such requirements will be satisfied by the CONTRACTOR at no additional expense to the OWNER.
E. The Drawings and Specifications are complementary to each other; which is called for one shall be as binding as if called for by both. If a conflict between Drawings and Specifications is discovered, this shall be referred to the ENGINEER as soon as possible for resolution. Should a conflict exist between Drawings, Specifications, and/or mandatory requirements (i.e., codes, ordinances, etc.), it will be assumed that the more expensive method has been estimated, unless such alternate has been agreed to prior to submission of bids.
BC&A PROCESS CONTROL AND INSTRUMENTATION JVWCD SYSTEMS GENERAL CENTRAL PIPELINE PROJECT PAGE 17050-2
1.3 DEFINITIONS
A. Definitions: Definitions of terms and other electrical considerations as set forth in the:
1. National Electrical Code. 2. Institute of Electrical and Electronic Engineers. 3. International Society of Automation. 4. National Fire Protection Association. 5. National Electrical Testing Association.
1.4 SUBMITTALS
A. Furnish complete submittals in accordance with Section 16050 – Electric General Provision.
B. Product Data:
1. Complete manufacturer’s brochures identify instrument construction, accuracy, ranges, materials, and options. 2. Completed instrument data sheets including catalog number and source for determining catalog number. 3. Manufacturer’s installation instructions.
C. Shop Drawings:
1. Mechanical connection diagrams. 2. Sensor transducer mounting requirements with dimensions and elevations. 3. Electrical connection diagrams.
D. Test Reports:
1. Certified factory and field calibration data sheets for instruments and devices that require set-up and calibration. a. Including factory calibration for each instrument with stated accuracy.
E. Operating Manuals:
1. Certified factory and field calibration data sheets for instruments and devices that require set-up and calibration. a. Including factory calibration for each instrument with stated accuracy. 2. Complete installation, calibration, and testing manuals.
F. Record Drawings:
1. Complete field calibration sheets, including range, span, PLC I/O address, register, and scaling coefficients.
1.5 DELIVERY, STORAGE, AND PROTECTION
A. In accordance with Section 16050 – Electric General Provision.
BC&A PROCESS CONTROL AND INSTRUMENTATION JVWCD SYSTEMS GENERAL CENTRAL PIPELINE PROJECT PAGE 17050-3 1.6 WARRANTY
A. The Contractor shall guarantee the performance and the hardware of all the instrumentation, control, for a period of one year following the date of completion and formal acceptance of the WORK.
PART 2 – PRODUCTS
2.1 MATERIALS
A. All materials and equipment furnished under this contract shall be new, free from defects, and shall be standard products produced by manufacturers regularly engaged in the manufacturer of these products.
B. Where there is more than one item of similar equipment being furnished under this contract, all such similar equipment shall be the product of a singular manufacturer.
C. All meters, instruments, and other components shall be the most recent field proven models marketed by their manufacturers at the time of submittal of the shop drawings unless otherwise specified to match existing equipment.
D. Signal Levels:
1. Analog measurements and control signals shall be as indicated herein, and unless otherwise indicated, shall vary in direct linear proportion to the measured variable. 2. Electrical signals outside control panels shall be 4 to 20 milliamperes DC except as indicated. 3. All electric signals shall be electrically or optically isolated from other signals.
E. All instrumentation shall be suitable for operation, in the ambient conditions at the equipment installation locations.
1. Heating, cooling, and dehumidifying devices shall be incorporated with the outdoor and/or indoor instrumentation in order to maintain it within its rated environmental operating ranges. 2. All enclosures shall match the area classifications as detailed in Section 16050.
F. Instruments to be furnished and installed on this project are listed in the following Instrumentation Schedule.
BC&A PROCESS CONTROL AND INSTRUMENTATION JVWCD SYSTEMS GENERAL CENTRAL PIPELINE PROJECT PAGE 17050-4
JVWCD CENTRAL PIPELINE PROJECT INSTRUMENTATION SCHEDULE
Pressure Gauges Device Tag Device Description Range Set Point Notes Drawing CPJN-PI-01 HOUSE WATER 0 - 150 psig FL-I-2 PRESSURE CPJN-PI-02 CARRIER WATER PUMP 0 - 150 psig FL-I-2 DISCHARGE PRESSURE CPJN-PI-03 CHEMICAL FEED PUMP 0 - 150 psig FL-I-2 DISCHARGE PRESSURE CPJN-PI-04 CENTRAL PIPLINE 0 - 250 psig M-1 UPSTREAM PRESSURE OF MAIN LINE VALVE CPJN-PI-05 CENTRAL PIPLINE 0 - 250 psig M-1 DOWNSTREAM PRESSURE OF MAIN LINE VALVE CP150-PI-01 150TH PIPELINE WEST 0 - 250 psig M-3 BRANCH PRESSURE CP150-PI-02 CENTRAL PIPELINE 0 - 250 psig M-3 PRESSURE CP150-PI-03 150TH PIPELINE EAST 0 - 250 psig M-3 BRANCH PRESSURE Pressure Transmitters
Device Tag Device Description Range Set Point Notes Drawing
CPJN-PE/PIT-01 CENTRAL PIPLINE 0 - 250 psig ROSEMONT MODEL 3051T E-3 UPSTREAM PRESSURE OR ENDRESS + HAUSER OF MAIN LINE VALVE MODEL PMP 71 CPJN-PE/PIT-02 CENTRAL PIPLINE 0 - 250 psig ROSEMONT MODEL 3051T E-3 DOWNSTREAM OR ENDRESS + HAUSER PRESSURE OF MAIN MODEL PMP 71 LINE VALVE CPJN-PE/PIT-03 CENTRAL PIPLINE 0 - 250 psig ROSEMONT MODEL 3051T FL-I-2 PRESSURE AT OR ENDRESS + HAUSER FLUORIDE BUILDING MODEL PMP 71 CP150-PE/PIT-01 150TH PIPELINE WEST 0 - 250 psig ROSEMONT MODEL 3051T E-7 BRANCH PRESSURE OR ENDRESS + HAUSER MODEL PMP 71 CP150-PE/PIT-02 CENTRAL PIPELINE 0 - 250 psig ROSEMONT MODEL 3051T E-7 PRESSURE OR ENDRESS + HAUSER MODEL PMP 71 CP150-PE/PIT-03 150TH PIPELINE EAST 0 - 250 psig ROSEMONT MODEL 3051T E-7 BRANCH PRESSURE OR ENDRESS + HAUSER MODEL PMP 71
BC&A PROCESS CONTROL AND INSTRUMENTATION JVWCD SYSTEMS GENERAL CENTRAL PIPELINE PROJECT PAGE 17050-5 Fluid Level Sensors
Device Tag Device Description Range Set Point Notes Drawing
CPJN-LE/LIT-01 FLUORIDE STORAGE 0 - 8 ft. HHWL 7 ft. RADAR LEVEL SENSOR; FL-I-1 TANK NO. 1 LEVEL HWL 6.67 ft. ENDRESS + HAUSER LWL 1.5 ft. MODEL FMR LLWL 0.67 ft. CPJN-LE/LIT-02 FLUORIDE STORAGE 0 - 8 ft. HHWL 7 ft. RADAR LEVEL SENSOR; FL-I-1 TANK NO. 2 LEVEL HWL 6.67 ft. ENDRESS + HAUSER LWL 1.5 ft. MODEL FMR LLWL 0.67 ft.
CPJN-LE/LIT-03 FLUORIDE DAY TANK 0 - 4 ft. HHWL 2.67 ft. RADAR LEVEL SENSOR; FL-I-1 LEVEL LLWL 0.5 ft. ENDRESS + HAUSER MODEL FMR Fluid Level Switches
Device Tag Device Description Range Set Point Notes Drawing
CPJN-LSH-01 FLUORIDE 0 - 6 IN 1 INCH FLOAT TYPE; GEMS MODEL FL-I-1 CONTAINMENT LEVEL NO. 01702
CPJN-LSH-02 CHEMICAL METERING - MOISTURE SENSOR FL-I-2 PUMP LEAK DETECTION CPJN-LSH-03 CENTRAL PIPELINE 0 - 6 IN 1 INCH FLOAT TYPE; GEMS FL-I-2 METER VAULT LEVEL MODEL NO. 01702
CPJN-LSH-04 CHEMICAL INJECTION 0 - 6 IN 1 INCH FLOAT TYPE; GEMS FL-I-2 VAULT LEVEL MODEL NO. 01702
CPJN-LSH-05 MAIN LINE VALVE 0 - 6 IN 1 INCH FLOAT TYPE; GEMS E-3 VAULT LEVEL MODEL NO. 01702
CPJN-LSH-06 BLUFFDALE TURNOUT 0 - 6 IN 1 INCH FLOAT TYPE; GEMS E-4 METER VAULT MODEL NO. 01702
CJ150-LSH-01 150th VALVE VAULT 0 - 6 IN 1 INCH FLOAT TYPE; Gems E-7 LEVEL Model NO. 01702
Fluid Flow Switches Device Tag Device Description Range Set Point Notes Drawing
CPJN-FSL-01 CARRIER WATER PUMP - - FLOWTECT MODEL FL-I-2 DISCHARGE FLOW V6EPBBS4B, OR EQUAL
CPJN-FSH-01 EMERGENCY EYE - - FLOWTECT MODEL FL-I-1 WASH/SHOWER NO. 1 V6EPBBS4B, OR EQUAL; FLOW SPECIFICATION 15420 CPJN-FSH-02 EMERGENCY EYE - - FLOWTECT MODEL FL-I-2 WASH/SHOWER NO. 2 V6EPBBS4B, OR EQUAL; FLOW SPECIFICATION 15420
Fluid Flow Meters Device Tag Device Description Range Set Point Notes Drawing
CPJN-FE/FIT-01 FLUORIDE BUILDING - - SEE SCHEDULE ON GM-3 FLOW METER DRAWING GM-3
CPJN-FE/FIT-03 BLUFFDALE METER - - SEE SCHEDULE ON GM-3 VAULT FLOW METER DRAWING GM-3
BC&A PROCESS CONTROL AND INSTRUMENTATION JVWCD SYSTEMS GENERAL CENTRAL PIPELINE PROJECT PAGE 17050-6 Water Analyzers
Device Tag Device Description Range Set Point Notes Drawing
CPJN-AE/AIT-01 CENTRAL PIPELINE ANALYTICAL FL-I-2 CHLORINE RESIDUAL TECHNOLOGIES, INC ANALYZER MODEL Q46H CPJN-AE/AIT-02 CENTRAL PIPELINE ANALYTICAL FL-I-2 FLUORIDE TECHNOLOGIES, INC CONCENTRATION MODEL Q46F ANALYZER Intrusion Switches
Device Tag Device Description Range Set Point Notes Drawing CPJN-ZS-01 MAIN LINE VALVE E-3 VAULT ACCESS LID POSITION CPJN-ZS-02 MAIN LINE VALVE E-3 VAULT ACCESS LID POSITION CPJN-ZS-03 BLUFFDALE METER E-4 VAULT ACCESS LID POSITION CPJN-ZS-04 FLUORIDE BUILDING FL-I-2 ELECTRICAL ROOM CPJN-ZS-05 FLUORIDE BUILDING FL-I-2 METER ROOM CPJN-ZS-06 FLUORIDE BUILDING FL-I-1 CHEMICAL ROOM CP150-ZS-01 150th VALVE VAULT E-7 ACCESS LID POSITION CP150-ZS-02 150th VALVE VAULT E-7 ACCESS LID POSITION Weight Scale
CPJN-WE/WIT-01 CHEMICAL DAY TANK SPECIFICATION FL-I-1 WEIGHT SECTION 11258
PART 3 – EXECUTION
3.1 INSTALLATION
A. General: as part of its role as Electrical Contractor, and in accordance with the manufacturer’s instructions, and in coordination with the ENGINEER and the OWNER, all systems specified and/or required shall be:
1. Installed. 2. Connected. 3. Calibrated. 4. Tested. 5. Started to place the system in operation. 6. This shall include final calibration in concert with equipment specified elsewhere in these Contract Documents.
BC&A PROCESS CONTROL AND INSTRUMENTATION JVWCD SYSTEMS GENERAL CENTRAL PIPELINE PROJECT PAGE 17050-7 B. It is the intent of the specifications that the Contractor shall accomplish the physical installation of all elements, instruments, accessories or assemblies specified in these document contracts.
1. The Instrumentation and Control System Contractor shall employ installers who are skilled and experienced in the installation and connection of elements, instruments, accessories and assemblies. 2. Electrical work shall be performed as specified in the applicable sections of Division 16.
C. The monitoring and control system configurations are diagrammatic.
1. The locations of equipment are approximate unless dimensioned. 2. The exact locations and routing of wiring and cables shall be governed by structural conditions and physical interferences and by the location of electrical terminations on equipment. 3. Where job conditions require reasonable changes in approximated locations and arrangements, the Contractor shall make such changes without extra cost to the OWNER, in accordance with the requirements of Division 16.
D. All equipment shall be located and installed so that it will be readily accessible for operation and maintenance.
1. The OWNER reserves the right to require minor changes in location of equipment prior to roughing in without incurring any additional costs or changes.
E. Installation and Connection: the Contractor shall install and connect all field-mounted components and assemblies under the criteria imposed by these specifications.
1. The installation personnel shall be provided with a final reviewed copy of the shop drawings and data. F. Conduit, Cables, and Field Wiring:
1. All conduit shall be provided under Division 16 without delay to the WORK of Division 17. 2. All 4-20 mA signal circuits, process equipment control wiring, signal wiring to field instruments, PLC input and output wiring and other field wiring and cables shall be provided under Division 16.
3.2 CLEANING
A. All control panels and enclosures shall be vacuumed clean prior to start-up and again after final completion of the project.
B. All panel surfaces shall be cleaned, any scratches and/or defects shall be repaired to “new” condition.
1. If in the ENGINEER’s opinion the panel repairs do not constitute ‘new” condition, they shall be replaced with new panels at no additional cost to the OWNER.
C. All instrument faces and enclosures shall be wiped and/or vacuumed clean.
END OF SECTION
BC&A PROCESS CONTROL AND INSTRUMENTATION JVWCD SYSTEMS GENERAL CENTRAL PIPELINE PROJECT PAGE 17050-8
SECTION 17421 FIBER OPTIC CABLE SUBSYSTEM
1 PART 1 GENERAL
1.1 REFERENCES
A. The following is a list of standards which may be referenced in this section:
1. Institute of Electrical & Electronics Engineers (IEEE): 802.3, Information Technology - Local and Metropolitan Area Networks - Part 3: Carrier Sense Multiple Access with Collision Detection (CSMA/CD) Access Method and Physical Layer Specifications. 2. Society of Cable Telecommunications Engineers (SCTE) Recommended Practices for Optical Fiber Construction and Testing. 3. Telecommunications Industry Association (TIA); Electronics Industry Association (EIA): a. 492, Specifications for Optical Waveguide Fibers. b. 568, Commercial Building Telecommunications Cabling Standard. c. 569, Commercial Building Standards for Telecommunications Pathways and Spaces. d. 607, Commercial Building Grounding and Bonding Requirements for Telecommunications e. GR-356-CORE Generic Requirements for Optical Cable Innerduct and Accessories f. GR-487-CORE Generic Requirements for Electronic Equipment Cabinets. g. GR-20 CORE Generic Requirements for Optical Fiber and Fiber Optic Cable. h. GR-771-CORE Generic Requirements for Fiber Optic Splice Closures i. TR-NWT-001121 Generic Requirements for Self-Supporting Optical Fiber Cable. j. GR-606 Labeling.
1.2 DEFINITIONS
A. Abbreviations:
1. OTDR: Optical time domain reflectometer. 2. FDDI: Fiber Distributed Data Interface. 3. PAT: Performance Acceptance Test 4. ORT: Operational Readiness Test
1.3 SYSTEM DESCRIPTION
A. This Section covers requirements for procurement, pre-installation testing, installation, post-installation testing, and commissioning of the fiber optic subsystem.
B. The Fiber Optic Cable Subsystem includes fiber cables, connectors, and accessories for a system wide installation as shown on the Drawings. For locations of equipment refer to Drawings.
BC&A JVWCD FIBER OPTIC CABLE SUBSYSTEM CENTRAL PIPELINE PROJECT PAGE 17421-1
1.4 SUBMITTALS
A. Action Submittals:
1. Shop Drawings: a. Bill of Materials: Listing of Fiber Optic Cable Subsystem equipment including: 1) Manufacturer. 2) Model numbers. 3) Description. 4) Quantity supplied. b. Component Data: 1) General data and descriptions. 2) Engineering specifications and data sheets. 3) Installation details. c. Cable Schedule Block Diagram: 1) Cable identifications. 2) Fiber counts for each cable with identifications of used fiber pairs. 3) Cable lengths and attenuation. 4) Transceivers. 5) Fiber optic jumpers. d. Performance data for each piece of equipment, that will show compliance with specification requirements and link calculations. e. Fiber identification sequence and labeling. f. Off-line maintenance aids and on-line diagnostics that check performance. g. Recommended spare parts list. h. Recommended special tools for installation, testing, and maintenance. 2. Samples: Fiber optic cable of sufficient length to show complete cable stamping.
B. Testing Related Submittals:
1. OTDR certification, current within last 6 months. 2. Submit two copies, minimum. 3. Pre-Installation Test Documentation. As specified under paragraph Pre- Installation Testing. 4. Post-Installation Test Documentation. a. As specified under paragraph Final Acceptance and Documentation. b. An updated version of the light budget spread sheet specified under paragraph Shop Drawings including: 1) Actual cable lengths used. 2) Actual losses measured by the tests.
C. O&M Manuals:
1. Updated versions of all Shop Drawings. 2. Post-Installation Test Documentation. 3. Component Manufacturers’ O&M Manuals: Include manuals to a cover installation, operation, maintenance, troubleshooting, and calibration.
BC&A JVWCD FIBER OPTIC CABLE SUBSYSTEM CENTRAL PIPELINE PROJECT PAGE 17421-2
4. List of spare parts and expendable provided and list of recommended spare parts.
1.5 QUALITY ASSURANCE
A. The supply, installation, and checkout of the fiber optic network shall be by a qualified fiber optic cable installer.
1.6 SEQUENCE AND SCHEDULING
A. Pre-Installation Testing Documentation submitted and approved prior to installation.
B. Post-Installation Testing Documentation submitted and approved prior to ORT.
1.7 SYSTEM PERFORMANCE
A. Provide a fiber optic Ethernet LAN that complies with IEEE Standard 802.3 and specifications for 1000BASE-LX.
2 PART 2 PRODUCTS
2.1 FIBER OPTIC CABLE
A. Cable Requirements:
1. As specified on drawings.
B. Cable Fabrication and Packaging:
1. Fibers within the cable shall be color-coded per TIA/EIA 598-A so that each fiber may be individually identified. 2. The outer jackets of the cable shall be continuous, free from holes, splits, blisters, or inclusions. The same requirement holds for any inner jackets within a given cable structure as well as for fiber coatings. 3. Materials used for fiber optic cable shall present no environmental or toxicological hazards as defined by current industry standards and shall comply with OSHA and EPA standard or applicable federal or state laws or regulations. 4. Outer polyethylene jacket materials shall meet tensile strength and elongation minimum requirements for unaged and aged samples as follows: a. Tensile Strength at Break: 1) Unaged: 2,800 psi. 2) Aged: 2,100 psi. b. Elongation at Rupture: 1) Unaged: 400 percent. 2) Aged: 375 percent. 5. The cable jacket shrinkage test measures the shrinkage or expansion of a cable jacket exposed to temperature aging for a specified period of time. Maximum shrinkage shall be less than 5 percent for each specimen tested. The test procedure is described in EIA-RS-455, FOTP-86. 6. The cable shall be permanently marked with identification of the manufacturer, the date of manufacture, length markings, a product identification code, and UL
BC&A JVWCD FIBER OPTIC CABLE SUBSYSTEM CENTRAL PIPELINE PROJECT PAGE 17421-3
messages where appropriate. The markings shall be printed at regular intervals of not more than 2 feet apart. 7. The cable shall be packaged on a reel with inner hub diameter greater than the recommended minimum bending diameter of cable. The anchor holes on the reels shall admit a 2-1/2-inch diameter spindle with binding. The package shall be sturdy enough to endure reasonable handling during shipping and storage. The package shall bear the name of the manufacturer, the product identification code, and the total amount of product on the reel. 8. The following information shall be securely attached to the reel on a tag or clearly and permanently stenciled or labeled on each reel. a. Customer order number. b. Customer job number. c. Customer reel number. d. Termination. e. Shipping date. f. Manufacturer’s name. g. Factory reel number. h. Manufacturer’s cable code (type and fiber count). i. Length of cable. j. Weight of cable and reel. k. Defect tab. 9. The ends of all cable shall be sealed to prevent escape of filling compound and to keep out moisture during shipping, handling, storage, and installation.
2.2 FIBER CONNECTORS
A. Single mode fiber connectors for connecting in to patch panels shall be SC/APC type. SC/APC connectors shall meet JIS C5973 F04 connector specifications.
B. Multi-mode fiber connectors for connecting into patch panels shall be ST/APC type. ST/APC connectors shall meet JIS C5973 F04 connector specifications.
C. SC/APC connector insertion loss shall be less than or equal to 0.5 dB with a return loss less than or equal to minus 65 dB.
D. Durability: connector insertion loss characteristic increase after 500 matings shall be less than or equal to 0.2 dB.
E. Connectors shall have operating temperature of minus 40° to 185° F (-4° C to 85° C).
2.3 SPARE PARTS
A. Fiber Connectors: 12.
2.4 FIBER OPTIC CABLE INSTALLATION MATERIALS
A. Breakaway Swivel Connector: Machine roller bearing swivel shall allow fiber optic cable rotation during fiber optic cable pulling operations. Swivel connector shall incorporate a fusible link or internal shear pin to limit fiber optic cable tension to a maximum of 300 pounds or to match fiber optic cable manufacturers recommendations. Swivels shall be General Machine Products 15370A, or equal.
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B. Tie Wraps: Tie wraps for fasting fiber optic cable to racking shall be 1/4-inch by 18-inch black nylon fiber optic cable ties with 50 pounds maximum loop tensile strength.
C. Fiber optic cable Lubricant: High-efficiency fiber optic cable lubricant compatible with the fiber optic cable and innerduct, such as manufactured by Greenlee Tool; “Polywater F” as manufactured by American Polywater shall be used when pulling fiber optic cable and innerduct through long pipe sections. Lubricants used shall be compatible with the conditions at the time of the pull.
3 PART 3 EXECUTION
3.1 INSTALLATION
A. Raceways and Innerduct:
1. Installed under Division 16, ELECTRICAL. 2. One fiber optic cable per innerduct, maximum.
B. Fiber Optic Cable:
1. Follow cable manufacturer’s installation practice and specification. 2. Install cables in innerduct. 3. Conduit routings are shown on Drawings. Any cable lengths shown on Drawings are approximations only. Provide lengths required to perform installations as indicated on Drawings. 4. Install cable directly from shipping reels. Insure that cable is not: a. Dented, nicked, or kinked. b. Subjected to pull stress greater than or bend radius less than manufactures specification. c. Otherwise subjected to treatment which may damage fiber strands during installation. 5. When possible, the entire length of fiber optic cable shall be placed in one uninterrupted operation without intermediate assistance. 6. Lubrication shall be provided only if recommended by the equipment manufacturer and needed to minimize tension on the fiber optic cable. 7. The maximum pulling force on the fiber optic cable shall be 300 pounds or per fiber optic cable manufacturer’s recommendations. An approved fiber optic cable grip with pulling eye shall be attached to the fiber optic cable end. The pulling eye on the fiber optic cable grip shall be connected to the pulling line using a breakaway swivel connector. The breakaway swivel connector shall be calibrated to 300 pounds tension or as per the fiber optic cable manufacturer’s recommendations. The fiber optic cable shall be pulled off the top of the fiber optic cable reel by hand during fiber optic cable placement to maintain fiber optic cable slack and to prevent reverse bends. The fiber optic cable reel shall be tended for the entire pull. The running line dynamometer shall monitor the pull line tension just ahead of the capstan. 8. Fiber optic cable can be placed using pneumatic methods provided the equipment is appropriate to the allowable tensile forces, the diameter of the fiber optic cable, and the conduit utilized. Care is to be exercised during the blowing operation to feed the fiber optic cable in the equipment loosely and with no
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tensile force. A sponge shall be used to clean the fiber optic cable of any dirt as it enters the conduit. 9. In the event that a fiber optic cable pull becomes too difficult in a buried section, excavation of the conduit may be required. The pipe or duct shall be exposed, cut, and the fiber optic cable pulled through. After the fiber optic cable is placed, the pipe or duct shall be covered with an approved pull box. 10. Fiber optic cable minimum bend radius for pulling through enclosures is 24 inches. 11. Sealing: Seal cables into conduits to stop ingress of water and grit with fabricated expansion plugs.
C. Splices:
1. Splice in accordance with the fiber splicing standards and procedures as outlined in the “Recommended Practices for Optical Fiber Construction and Testing” manual offered by the SCTE. Section 8 details the fiber splicing methods and procedures. Sections 10 and 11 cover fiber testing and include forms useful for recording test data. Pre-approval of alternate fiber splicing forms and formats are required. 2. All fiber splicing shall be fusion spliced. Acceptable losses are less than or equal to 0.10 dB for each fusion splice. 3. Each fusion splice shall be protected and placed in a splice tray and outdoor enclosure. At each splice location, each cable sheath shall have a minimum of 50 feet additional cable for future splicing activity and splice maintenance access purposes. 4. All fusion splices shall be done by a fiber core alignment system. Mechanical splices will be allowed only in emergency restoration and shall be replaced with fusion spices. 5. The fusion welders shall be equipped with a launch and detect feature to provide a go-no-go test during the splicing process. Environmental conditions such as humidity, dust, wind and cold can have a very negative effect on the fusion process. An environmentally controlled enclosure shall be used for all splicing activities.
D. Fiber Optic Cable Racking in Manholes and Handholes:
1. After fiber optic cable placement, all pulling hardware and lubricant shall be removed. 2. Racking shall be started at the center manhole and proceed in each direction simultaneously towards the fiber optic cable ends. 3. The necessary fiber optic cable slack shall be pulled by hand. Use caution when pulling fiber optic cable to prevent damage. 4. The fiber optic cable shall be covered with split innerduct, if bare, and laid on the racking shelves along the sidewalls at the same height as it enters and exits the manhole. All bends shall be gently formed to the greater of a minimum 24-inch diameter or 20 times the fiber optic cable diameter. 5. Innerduct with fiber optic cable shall be secured to the manhole hardware using lightweight plastic tie wraps. 6. Intermediate manholes/handholes with fiber optic cable in coils shall be gently formed to a minimum 24-inch diameter and secured to the manhole hardware in
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a safe location using plastic tie wraps. Fiber optic cable coils shall not be covered with split innerduct.
E. Termination at Fiber Patch Panel:
1. Fan out fiber cable to allow direct connectorization of fiber optic cable. 2. Sleeve over individual fiber with kevlar reinforced furcation tubes. 3. At point of convergence of furcation tubes, provide strain relief with high density plastic fan-out collar. 4. Terminate all fibers in cable.
F. Identification:
1. Identify each cable on both ends and pull points it goes through. 2. Identify with tags as directed by engineer or owner. 3. Use waterproof tags and identifications.
G. Fiber Storage:
1. Stored fiber cable shall be adequate to ring cut the cable sheath and splice the appropriate fibers in the future. Provide cable storage lengths as shown below. a. All Facility Entrance Locations and Risers (Per Sheath): 50 feet. b. All Underground Vaults: 100 feet. c. Locations Identified as Storage on Schedule: 200 feet. d. Splice Location: 200 feet. 2. Excess fiber optic cable in manholes and handholes shall be coiled by hand while maintaining minimum 24-inch diameter coil. The fiber optic cable shall be coiled from the fiber optic cable end toward the conduit face of the handhole. Bundle the turns of the coil together with loosely applied plastic tie wraps or electrical tape at several locations on the circumference of the coil. 3. The ends of the innerduct occupied by the fiber optic cable shall be sealed with a split rubber plug or an industry standard duct seal at handholes, manholes, building entrances or vaults. Spare innerducts shall be sealed with outside cover caps.
3.2 FIELD QUALITY CONTROL
A. Provide equipment, instrumentation, and supplies necessary to perform testing. Equipment shall bear current calibration certification from a certified instrument calibration laboratory. PROJECT REPRESENTATIVE shall have option to witness and participate actively in onsite tests.
B. General
1. Fiber loss test procedures shall follow the “Recommended Practices for Optical Fiber Construction and Testing” manual published by the Society of Cable Telecommunications Engineers. Section 10, “Field Testing of Single-Mode Optical Fiber Systems” details the fiber testing procedures that are used to determine compliance with the Loss Budget. Section 11 includes forms useful for recording test data.
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C. Pre-Installation Cable Testing:
1. All fiber optic cables shall be visually inspected and optically tested immediately after receiving the cable shipment. Testing shall ensure that fiber optic cables delivered to the construction contractor are within specification. The scale of the OTDR trace shall be such that the entire circuit appears over as much of the X- axis as possible 2. Use an OTDR (Optical Time Domain Reflectometer), an access jumper with like fiber and a 1 km pigtail (fiber jumper with a connector on one end). 3. Either mechanical splices or a bare fiber adapter (splice bushing) with index matching gel shall be used on all fibers to be tested for continuity and attenuation. 4. Two operating wavelengths (1310 nm and 1550 nm for single mode fiber) are required. 5. Testing of every fiber is required in only one direction. 6. Documentation: Hard copy and electronic copy of OTDR plots for each fiber.
D. Installation/Splicing Testing:
1. All testing shall conform with the “SCTE Recommended Practices for Optical Fiber Construction and Testing” manual. 2. Fiber plant shall be tested in segments, from patch panel to patch panel. 3. Each connectorized link shall be measured after complete installation. 4. End-to-End Attenuation Test: a. Test end-to-end attenuation with a light source and power meter to measure optical power loss between termination points. Two wavelengths shall be measured: 1310 nm and 1550 nm for single mode fiber. b. End-to-end attenuation, system loss must be below the designated loss budget. The loss values are dependent upon system actual length, wavelength, and number and type of splices and connectors. 5. OTDR Test: a. OTDR (Optical Time Domain Reflectometer) attenuation tests quantitatively measure the installed fiber system and its components. b. The scale of the OTDR trace shall be such that the entire circuit appears over as much of the X-axis as possible. c. The attenuation measured shall be independent of launch direction. d. Provide signature traces with length measurements as well as any anomalies in the installed cable plant. Trace files shall be saved for each bi-directional test. Special attention shall be made to dead zone jumpers and connectors. 6. Test Documentation for each fiber: a. Hard copy and diskette copy of OTDR plots. b. Results of bi-directional test with power meter and light source.
E. Final Acceptance and Documentation
1. Test results and analysis shall be detail each fiber showing each test result. Content shall mirror the SCTE Recommended Practices for Optical Fiber Construction and Testing” manual fiber routing/splicing forms.
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2. Link loss results from the end to end attenuation measurements shall be considered as most accurate method when results are in conflict. 3. Trace information may be submitted in electronic form. 4. Test Documentation: Test procedures, forms, and checklists. Signed by PROJECT REPRESENTATIVE and CONTRACTOR.
F. Loss Budget
1. All tests must meet or exceed the calculated loss budget. 2. The Loss Budget for any segment of the fiber optic cable network shall be calculated in a manner consistent with the following example Loss Budget :
IFP Loss Budget
Fiber Link Distance = 66,100 Ft. Fiber Storage = 5,200 Ft. Total Fiber Distance = 71,300 Ft. = 21.7 km Number of Field Fusion Splices* = 2 Maximum Loss per Fusion Splice = 0.1 dB 1310 nm 1550 nm All Wave Fiber Loss (.35/.20 dB per km at 1310/1550) = 7.595 4.340
Transmit Test Jumper Loss** = 0.78 dB 0.78DB Coupler Loss = 0 dB/leg 0 DB/leg Patch Panel Loss*** = 0 dB 0 DB Splice Tray CW = 0 dB 0 DB Splice Tray CCW = 0 dB 0 DB Field Fusion Splice Loss = 0.2 dB 0.2 DB Receive Test Jumper Loss** = 0.78 dB 0.78 DB Total Link Loss = 9.355 dB 6.100 DB
* Adjust if additional fusion splices required. ** Assume 3 SC/APC connectors at .25 dB loss ea. & 50’ of Single Mode Fiber. *** Assume 4 SC/APC connectors at .25 dB loss ea. & 115’ of Single Mode Fiber.
END OF SECTION
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